Hi ya all! I've been readin'...and studyin' the wire diagrams. Little bit of confusion ... I got this cart and the history is not great. Before I got it, it has had a new Electrical Component Box put in...cuz the other one burned up!! (makes ya go umm??) Someone put a new box in and supposedly fix and put new solenoid in...(I ask myself...well did they figure out what caused the burn up?) Anyhoots, here I am...the solenoid has burned up again. Now I'm saying to myself...somebody's missing the real cause-issue of all this. So, I bought a new solenoid, put it on. hooked it up the way they had it...got it running...got the tester out and I was already gettin' spikes! Ok, so I printed out a color diagram of the wires and traced them all to where they should go. In the course of all this I found the ground not hooked up from the voltage regulator and it smelled burnt, so without out hesitation I replaced the Volt Reg. Ok so now we have nice new solenoid and volt reg hooked up right according to the color wire diagram. As I triple check all the wires to where they go...I find that the diode that goes across from the small terminals is missing! I read that along with volt reg they both are anti-spike helpers. So..I order the missing diode and put it on properly as showed in the color wire diagram, Orange wire on solenoid-hot- diode "band" side. then the blue wire on solenoid(goes to ign switch) is the other end of the diode. The diodes purpose is to be "one way" and to protect other components. Well, I put that on as exactly shown. Hook bat up... turn key, press gas pedal....and NOTHING! So I take off the Orange side of diode and cart starts up! WHA!? So, it's acting like perhaps I have a bad ign switch? I also find it interesting that when tried in reverse, the buzzer is not heard...umm??
So then what do I do? I wanted to find a wire diagram that included the RPM limiter into the picture of wires where as the color diagram does not. What do I find? I put in 2002 DS Club Car wire diagram for google...and I come up with a 234page PDF and section 6G I find an awesome wire diagram! The problem? LOL, it does NOT show that there's a diode needed across the small terms of the solenoid...and the big wires(white and red) that are hooked to the solenoid are opposite of what the color diagram shows...but that should not matter right? On this cart, the wires are put on as this pdf shows! so I'm gonna leave that alone...but huh? why not show a diode on the small terms? The mass majority of wire diagrams we find on the net....are like the color diagram...showing a must have diode...?? huh?
Most people would say.....walk away...you got it running and that's good enough. I'm just not comfortable here. I feel I do not want to miss something that's been causing someone else headaches...perhaps they and myself are overlooking something simple here? I'd like to avoid another burn up by all means. I've got this "itch" that I should replace the ign switch. But, I'm a guy that likes to take out the testers and find the exact part that's not working or causing a problem, instead of throwing parts until problem solved. Anyone have any thoughts here? BTW, not that it matters, I've taken all ground contacts and cleaned them so that ground is good...I did that after finding the black ground wire not hooked up to the micro switch from the volt reg. I've seen in the past where bad ground connections have caused issues...so while I'm in there...I cleaned the connections!! Anyhow, sorry for the long post, but, thought I need to provide the "did's" before someone can help with an idea where I should go...anyway can I "test" the ign switch?(or is it one of those things...just spend the 20$ and put a new one in?)
THANKS IN ADVANCE FOR ANYONE's HELP!
So then what do I do? I wanted to find a wire diagram that included the RPM limiter into the picture of wires where as the color diagram does not. What do I find? I put in 2002 DS Club Car wire diagram for google...and I come up with a 234page PDF and section 6G I find an awesome wire diagram! The problem? LOL, it does NOT show that there's a diode needed across the small terms of the solenoid...and the big wires(white and red) that are hooked to the solenoid are opposite of what the color diagram shows...but that should not matter right? On this cart, the wires are put on as this pdf shows! so I'm gonna leave that alone...but huh? why not show a diode on the small terms? The mass majority of wire diagrams we find on the net....are like the color diagram...showing a must have diode...?? huh?
Most people would say.....walk away...you got it running and that's good enough. I'm just not comfortable here. I feel I do not want to miss something that's been causing someone else headaches...perhaps they and myself are overlooking something simple here? I'd like to avoid another burn up by all means. I've got this "itch" that I should replace the ign switch. But, I'm a guy that likes to take out the testers and find the exact part that's not working or causing a problem, instead of throwing parts until problem solved. Anyone have any thoughts here? BTW, not that it matters, I've taken all ground contacts and cleaned them so that ground is good...I did that after finding the black ground wire not hooked up to the micro switch from the volt reg. I've seen in the past where bad ground connections have caused issues...so while I'm in there...I cleaned the connections!! Anyhow, sorry for the long post, but, thought I need to provide the "did's" before someone can help with an idea where I should go...anyway can I "test" the ign switch?(or is it one of those things...just spend the 20$ and put a new one in?)
THANKS IN ADVANCE FOR ANYONE's HELP!
