1995 Club Car DS 48V stalls out at full acceleration

[mako305]

Hi All,

My first tech issue post, but have found all of the messages very helpful. I have a 95 Club Car DS 48V. After taking it apart to paint, upgrade lights add stereo and replace batteries, I ran into a few issues when putting it all back together. First issue was that the solenoid wasn't clicking. It was replaced and looks to have been resolved, the cart would move again. But now the cart stalls out when I press the throttle all the way.

Its a 1995 with a Pot Box. I tested the Ohms at the controller. I would get 6.1K at rest and as I pressed the accelerator it would drop to about 3K before spiking up to various numbers never getting close to 0 or below 3K even.

Spoke to my local cart guy and we then decided to test bypassing the microswitch in the potbox by jumping the blue and green/white wires connected to the microswitch to ensure the pot box was the issue before gong out and purchasing the MCOR4 conversion kit. The cart still stalls out at full throttle just like if it was still connected to the pot box.

Not sure if our assumption of bypassing the pot box micro switch is incorrect or if I may have another issue like the controller. Any advise would be greatly appreciated. Thanks

[Ryokuro]

To me it sounds like your potbox is the issue. It's either 0-5K or 5K-0. Hopefully the attached image will help you figure out which you should have.

[mako305]

Thanks for the reply. Couple more questions. Wouldn't bypassing the micro switch in the pot box have avoided the stall?

Also, my configuration is not the same as in the table you shared. I have a 95 serial A9542. I know they changed the pontentiometer mid year. My controller is silver and I'm pretty sure its 0-5K.

[mako305]

Update - Installed MCOR4 conversion kit #AM293201 and fixed the issue.