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Old 10-04-2018, 03:19 PM   #1
gpmclaughlin
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Default 2001 DS forward reverse switch heat issues

Hi everybody, I'm looking for a little advice regarding a 2001 DS forward reverse switch heat issue.
I recently purchased this Club Car and absolutely love this cart.
The problem I ran into shortly after purchase was that the f/r switch M-cable (Blue) melted the switch connection located on the inside of the switch to the point that the cart would not engage in either gear.
I replaced the switch with a heavy duty one and the cart now runs fine but the orange (S2) cable to the motor is very hot to the touch after use.
The odd thing is the cable is hot only at the switch not at the motor. I can only assume the M - cable is heating up as well due to the previous meltdown.
The cart has 6 gauge wiring and no other cables even get warm.

Any ideas?

Thanks!
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Old 10-05-2018, 09:20 AM   #2
BBBHC
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Default Re: 2001 DS forward reverse switch heat issues

My first thought would be a loose connection or possibly a "break" in the wire some where?
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Old 10-05-2018, 10:13 AM   #3
Raystar57
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Default Re: 2001 DS forward reverse switch heat issues

Could be a bad crimp in the cable end.
They may look good but inside the crimp could be making poor connection.
This resistance will cause heat build up on that terminal.
I would replace the compete cable or at least redo the crimp correctly.
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Old 10-06-2018, 11:54 AM   #4
gpmclaughlin
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Default Re: 2001 DS forward reverse switch heat issues

Quote:
Originally Posted by Raystar57 View Post
Could be a bad crimp in the cable end.
They may look good but inside the crimp could be making poor connection.
This resistance will cause heat build up on that terminal.
I would replace the compete cable or at least redo the crimp correctly.
I appreciate both of your responses. I was looking for the replacement cables and cannot find them online, only battery cable replacements. Any idea where I can find these cables online?
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Old 10-06-2018, 03:54 PM   #5
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Default Re: 2001 DS forward reverse switch heat issues

Just an update...
Could not easily find replacement cables so I resorted to grade school chemistry class.
I took the cable ends and soaked them in Coca Cola for an hour even though I could not see any corrosion. It did bubble up a bit however.
Sure enough, problem solved. Cables get warm but not hot at the switch.
So after an $89.00 switch and a 75 cent Coke, the problem is solved.
Crazy, huh?
Still kind of strange that I couldn’t find replacement cables on line though.
Thanks for your help!
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Old 10-07-2018, 11:05 AM   #6
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Default Re: 2001 DS forward reverse switch heat issues

Glad you got it working! I'm not sure if there would be a replacement "kit" for those. If they are anything like my setup, they are part of the entire wire harness. Something like this:https://www.ecartparts.com/golf-cart...ts-club-car-ds
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Old 10-07-2018, 11:14 AM   #7
Fairtax4me
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Default Re: 2001 DS forward reverse switch heat issues

You want to replace those cables.Internal Damage from overheating at the connection has already been done and you will continue to have problems in the future. Heat is caused by resistance to the flow of electrical current. When a cable or connection gets too hot it damages the cable which creates more resistance, and thus more heat. It’s a snowball effect.
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Old 10-09-2018, 04:26 PM   #8
gpmclaughlin
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Default Re: 2001 DS forward reverse switch heat issues

I agree! I would love to switch out those cables but I just cannot find them anywhere as yet. The wiring harnesses referenced above are actually only for battery powered accessories like turn signals, light switch and headlights and all other sites are extremely happy to sell you battery cables but no switch cables as yet.
These cables have different size terminals from the switch to the motor S2 connection and the M- connection!
As I said, the 75 cent Coke has temporarily (?) solved the issue and I will keep a close eye on that. I may have to visit a Club Car cemetery for replacements.
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