Posted Earlier: 89 EZ GO Marathon Smoked Cable

[koob]

Well after tightening all the connections I thought it was fixed. I used it a lot yesterday and the thing started smelling like burned plastic again and it was the same cable. It goes from the 4 position (rheostat?) new here so I don't know the proper name, to the last post on the resistor box. Then another cable attached to it goes to the motor. Am I correct in assuming (I know) that the #4 position is the fastest speed and sends full voltage around the resistors and directly to the motor? The top of the resistor box is a fiberglass looking board where all the lugs are and the last one that has burned has about ate up the fiberglass. All the resistors are good and the cables look good even though they have smoked several times but I cleaned them all and it works fine for a while then starts smoking. Does the resistor board need replacing or can I run a cable from #4 at the rheostat? directly to the motor?

[mauistardog]

You can, but you will loose the lower end speed. The slow speed you get when you first start off is from the current going through all resister coils before exiting to the motor. the top speed, as you noticed, skips all the coils, but the other speed skips them one at a time. So if you bypass the last one, your take off will be faster. no slow speed. When I replaced my I just bought a whole new set up. cost like 80 bucks for new board with coils.

aloha
joe

[koob]

OK, finally able to get a photo up. I see what you mean Maui, what if I left the cables as is and then added a cable from #4 straight to the motor?

[Marathon Man]

I had an old cart with resistor coils bought an upgraded resistor coil assembly and upgraded to 4 gage cables and high speed motor once a cable gets hot its junk

[snaganddrag]

I have a 89 Marathion and am having the same problem with mine, as well as very little power. Let me know what you do too fix it. I have ordered new cables for mine

[mauistardog]

Originally Posted by koob

OK, finally able to get a photo up. I see what you mean Maui, what if I left the cables as is and then added a cable from #4 straight to the motor?

I don't think you will see much difference. The only resistance is wire. I changed everything to 4ga on my old one. I know other who have gone 2ga. most say 2ga is not worth it. It is only wire so I say try it. the only draw back i can see is your are stacking up wire lugs on each other, so more points to get loose.
joe