2002 Club Car DS Speed Sensor?

[Dave00]

Guys,

I'm new here and new to the golf cart world. I'm brining an older Club Car DS (2002) back to life for my parents as a Christmas present to give them something to puddle around the neighborhood in to visit friends. Cart has new batteries (6 Trojans - 48V total) and runs like a champ, except it seems to struggle on inclines and hills. I just replaced the solenoid/coil as it was not olm'ing out properly and would not click and the new one works like a champ, however, I know one of the major causes of incline speed reduction is the speed sensor, but this one does not have one on the back of the motor? Anyone know where I should look other than the Solenoid/Coil and the MCOR on this model. Here's some pics for reference and the pic has the older Solenoid installed and I just replaced it this morning. Any advise is greatly appreciated.

 

[Tom47]

This is a series drive cart and does not have a speed sensor. Only sepex carts have one. Your lack of hill climbing ability is typical of series carts.

The weak point in the system is the F/R switch. Since all motor current runs through this switch, any contact in it that is burned or dirty can slow the cart on hills.

See if the switch gets hot during operation especially on hills. Use an infrared heat gun to check it before the ride, during and after. If it is very hot, above 140 degrees, there probably are bad connections or contacts.

 

[Dave00]

This is a series drive cart and does not have a speed sensor. Only sepex carts have one. Your lack of hill climbing ability is typical of series carts.

The weak point in the system is the F/R switch. Since all motor current runs through this switch, any contact in it that is burned or dirty can slow the cart on hills.

See if the switch gets hot during operation especially on hills. Use an infrared heat gun to check it before the ride, during and after. If it is very hot, above 140 degrees, there probably are bad connections or contacts.

Tom, thank you and that is good to know as I didn't know there was a difference in DS cars (Series and Sepex). I removed the switch and took it apart to clean all the copper contact surfaces and clean any corrosion with a bit of sand paper on the contacts and also used a wire wheel on all the hardware as well as all of the battery cables and connections to shine/clean them up. Cart still seems the same and a little on the slow side, but could just be normal. Anything I should look at regarding the motor? I'm just concerned as we're (my brother and I) adding the rear seat kit (getting rid of the golf bag carrier and supplies) to give my parents some extra seats for the grandkids. However, I'm concerned that the extra weight is just going to make it worse. Things I've done so far:

1. New Batteries (6 new Trojans)
2. All new suspension (shocks and all bushings replaced)
3. New MCOR
4. New Solenoid/Coil
5. Cleaned all contacts (wirebrush any corrosion - very little)
6. Added Digital battery gauge
7. New Wheels/Tires (stock size 8 - 18.5)
8. Ordered new microswitch for the reverse buzzer as I can't get it to work (new buzzer installed) so I think it's the microswitch

Is there anything I should be looking at with the motor - cleaning the brushes?

 

[Tom47]

The motor brushes could need replacement. Also check the armature commutator at the same time. Unless those motor parts are worn, the motor is doing as much as it can.

Series carts were designed for golf courses with minor hills and two riders and 8 mph. We are asking them to do more than they were supposed to do. You may see 12 mph on level surfaces but only 6 to 8 on hills. That is about all you'll get for the stock setup.

Converting the cart to an IQ harness and a Navitas AC drive system (that I know nothing about but Diode does!) will cost north of $2000. They can reach speeds of 30 mph.

 

[Dave00]

Thanks Tom, I'll get it out later this week when the weather clears up and check the speeds with GPS to see if I'm where I should be. Don't wanna just throw parts at it unless they are needed.

 

[Diode]

I would say it could be done under $2,000 both the 4 KW 440a and 5 KW 600a.

 

[Tom47]

I would say it could be done under $2,000 both the 4 KW 440a and 5 KW 600a.

Probably, but he will need an IQ harness also.

OEM IQ harnesses are around $200 or so. I made the mistake of getting a non-oem one for my conversion. What a nightmare that was!

 

[Diode]

That's included and a throttle assembly I can do a 4K 440 for like 1550

 

[Tom47]

Great price! Where was this deal when I spent nearly 1800 to convert my regen 2 to IQ? I always miss out on the best options.

Except for my Eco Battery!

 

[Dave00]

Great price! Where was this deal when I spent nearly 1800 to convert my regen 2 to IQ? I always miss out on the best options.

Except for my Eco Battery!

Thank you guys, but I'm on a budget now to get this up and running for my folks for Christmas

It's running, just a little slower, but I'm assuming that is just the nature of the beast with this model. We'll see how it performs once we get the seat kit installed and my folks start using it. I'll leave it up to them if they want to upgrade and I'm sure I'll do the work for them if they want to spend the money.

 

[Tom47]

I can certainly understand the budget getting in the way of fun. It does that to me everyday!

I don't think having a slow cart is a bad thing, especially with the grandkids on board. My cart will do 25 easily but our average 10 mile plus rides are done around 12 mph. Much better to see the scenery!

 

[ShawnK]

Great price! Where was this deal when I spent nearly 1800 to convert my regen 2 to IQ? I always miss out on the best options.

Except for my Eco Battery!

I stopped getting upset about it a long time ago. The miser pays twice, so people say.

Thank you guys, but I'm on a budget now to get this up and running for my folks for Christmas

It's running, just a little slower, but I'm assuming that is just the nature of the beast with this model. We'll see how it performs once we get the seat kit installed and my folks start using it. I'll leave it up to them if they want to upgrade and I'm sure I'll do the work for them if they want to spend the money.

Do you mean to say that there's a bit of a lack of power feeling after this modification?

Hi all.

 

[Dave00]

I stopped getting upset about it a long time ago. The miser pays twice, so people say.

Do you mean to say that there's a bit of a lack of power feeling after this modification?

Hi all.

No, I haven't modified the cart as it's stock (Series Cart) with new batteries and new coil/solenoid. I pulled the new MCOR off and reinstalled the stock unit as it's functioning fine and don't need a new one. I did find that one of the new batteries is dropping below 7.8V over night after a full charge and I think it has a bad cell. I called my battery guy and he's swapping it out with a new one and we'll see how it performs after that. Not gonna set any land speed records with the stock setup, just wanna make sure it's functioning as it should from the factory before I hand it over to my folks at Christmas. If they want to upgrade it to the IQ setup (mentioned above) I'll leave that up to them for the cost and I'll be happy to do the work.

 

[Tom47]

No, I haven't modified the cart as it's stock (Series Cart) with new batteries and new coil/solenoid. I pulled the new MCOR off and reinstalled the stock unit as it's functioning fine and don't need a new one. I did find that one of the new batteries is dropping below 7.8V over night after a full charge and I think it has a bad cell. I called my battery guy and he's swapping it out with a new one and we'll see how it performs after that. Not gonna set any land speed records with the stock setup, just wanna make sure it's functioning as it should from the factory before I hand it over to my folks at Christmas. If they want to upgrade it to the IQ setup (mentioned above) I'll leave that up to them for the cost and I'll be happy to do the work.

I'm sure they will love the cart and you for doing this for them. That is a perfect Christmas present for anyone!

 

[Dave00]

That's included and a throttle assembly I can do a 4K 440 for like 1550

Diode, can you let me know where I can reach you as I wanted to ask some questions about your conversion kit? Thinking of going down that road now.

 

[Csimpler]

I have a 2000 with basically the same setup. I put a Plum Quick Bandit motor on it for about $300 and it runs about 20mph with little notice on hills. You'll here good and bad about Plum Quick, but they helped me with my decision and I've been happily driving Ms Nana around the trailerhood for ten years.