Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

[OLDESTCOWBOY]

I just replaced my stock 96 CC DS with HD's. (4 leaf) with new shocks
do to the fact of 12" wheels. I also rewired the complete cart with 2 guage
and replace all 12 volt lighting and acc. with new trailer cable and soldered
lugs. 14 gauge wire. The hardest job was the springs. I soaked the bolts
with plenty of rust buster and used all my air guns. (i am retired auto tech)
nothing worked until I got out the recip. saw and cut off the bolts. I replaced
all bolts with 3/8x 3 1/2 harden bolts with stainless flat washers and bolts.
Do not forget to grease all bushings and bolts, don't be stingy. I hope this
helps someone.
Bob

[Geezerbunny]

OK, I read all the advice about doing one side at a time and I still took off both U-bolts without jacking up the motor. As predicted, the axle and motor spun 90 degrees toward the front wheels. I got it all back to level with a wrecking bar and bolted the axle down to the new springs, Now everything looks normal, but my 2002 DS won't go forward or reverse -- it just sits there. The horn sounds off when I put it into reverse, but nothing else happens. I have checked for loose or broken wires, but nothing looks out of place. Any suggestions?

[Sergio]

According to your other posts you have an IQ cart.

Most likely the F1 or F2 spade connectors came loose from the Controller when the Motor twisted and pulled the wires.

[Geezerbunny]

Thanks, I have looked for loose wires but no luck so far. I'll keep trying.

Just FYI: The 2002 DS Owner's manual under General Information on page 12 says: There are three electric golf car models: the DS V-Glide (36-volt) vehicle, the DS PowerDrive System (48-volt) vehicle, and the DS IQ System (48-volt) vehicle.

[NoleFan4Ever]

If yours has a rocker switch for Fwd/Rev and a Run/Tow switch under the seat, it is an IQ (Sepex) cart.

The spade connectors Sergio is referring to are on the controller above the cables. They will be labled F1 F2 and may be behind a cover but they are attached on your controller. If they are still attached, check them for damage.

[NoleFan4Ever]

Originally Posted by crash test dummy

Brotherly support...

[Geezerbunny]

Success! Removed the seat backrest and the access panel cover and traced the F1 and F2 wires to the controller. Had to remove the black plastic cover from the controller, but the loose connector wire was easy to spot. Many thanks to Sergio and Nolefan4Life for pointing me in the right direction! My 2002 DS IQ is up and running on 20x8.5x8 tires on the rear. The HD springs lifted the rear just over 2 inches.

[NoleFan4Ever]

That's great!