Club Car DS Wiring Diagrams 1981 To 2002


GolfCartTips.com is a participant in affiliate services from Amazon and other affiliate programs. If you buy something through our links, as an Amazon Associate I earn from qualifying purchases. Check our legal information for more details.–

Club Car Golf carts have evolved many times since 1975, and although the basic electrical design has stayed close to the same, there are small differences. These differences are important when troubleshooting your cart.

Club Car DS Electric Models

Club Car DS 1981-85 Electric 5 Solenoid Type Wiring Diagram

Typical Diagram For Club Car DS Electric 5 Solenoid 1981-85
Typical Diagram For Club Car DS Electric 5 Solenoid 1981-85

Club Car DS 1986-94 Electric 5 Solenoid Type Wiring Diagram

Typical Diagram For Club Car DS Electric 5 Solenoid 1986-94
Typical Diagram For Club Car DS Electric 5 Solenoid 1986-94

Club Car DS 1995-2002 Electric 36 Volt V-Glide External Resistor Type Wiring Diagram

Typical Diagram For Club Car DS Electric V-Glide 1995-2002
Typical Diagram For Club Car DS Electric V-Glide 1995-2002

Troubleshooting Guide For Club Car DS Electric Models

SYMPTOMPROBLEM AREASPOSSIBLE CAUSES
Vehicle will not run - no "solenoid click"Batteries1. Battery connections
2. Discharged batteries
Key Switch1, Loose wires
2. Failed switch
Forward/Reverse Anti-Arcing
Micro Switch
1. Loose Wires
2. Failed Switch
3. Cam not Activating Micro Switch
Accelerator Linkage1. Accelerator rod disconnected or loose
Speed Controller Micro Switch1. Loose wire
2. Disconnected or loose wires
3. Failed switch
Solenoid1. Loose Wires
2. Failed solenoid coil
Vehicle will not run - "solenoid clicks"Forward/Reverse Switch1. Loose wires
2. Failed contacts
Motor1. Loose wires
2. Open windings
3. Worn out brushes
Solenoid1. Failed contacts
Cart Skips One Or More SpeedsSpeed Controller1. Loose or broken connections
2. Brush or contacts corroded, burned, or worn
3. Incorrect wiring
Resistors1. Loose or broken resistor
Cart Runs SlowSpeed Controller1. Loose or broken connections
2. Contacts corroded, burned, or worn
Batteries1. Loose or corroded terminals
2. Incorrect wiring
3. Battery failure
4. Batteries not fully charged
Accelerator Linkage1. Improper adjustment on accelerator rod
MotorLoose cables
2. Brushes worn or misaligned
3, Dirty commutator
Brakes1. Brakes dragging
Tires1. Flat or underinflated tires
Cart runs in first speed when F&R switch is in forward or reverse with key switched offSolenoid1. Solenoid contacts welded in closed position
Accelerator Linkage1. Misadjusted or bent accelerator rod
Speed Controller1. Pedal misadjusted
2. Stuck accelerator brush
Cart goes forward but not in reverse - or cart goes in revers and not forwardForward/Reverse Anti-Arcing
Micro Switch
1. Loose or broken wires
2. Switch not actuating properly
Forward/Reverse Switch1. suspect continuity of switch contacts
Cart not charging completelyCharger Connections1. Loose wires at F/R Switch, receptacle, or battery
1. Charger plug not fully engaged with receptacle
On Board Fuse1. Blown fuse
Charger1. Charger not receiving 115/120 volts, 15 amps
2. Charger faulty, not producing full output
3. Faulty cords or plugs

Club Car DS Gas Models

Club Car DS 1984-1985 Gas Model Wiring Diagram

Typical Diagram For Club Car DS Gas 1984-85 Older Version
Typical Diagram For Club Car DS Gas 1984-85 Older Version

There was a small change in the Limit Switch Wiring for later models of the same year.

Typical Diagram For Club Car DS Gas 1984-85
Typical Diagram For Club Car DS Gas 1984-85

Club Car DS 1986-1990 Gas Model Wiring Diagram

Typical Diagram For Club Car DS Gas 1986-90
Typical Diagram For Club Car DS Gas 1986-90

Club Car DS 1991 – 1997 Gas Model Wiring Diagram

Typical Diagram For Club Car DS Gas 1991-97
Typical Diagram For Club Car DS Gas 1991-97

Club Car DS 1998 – 2011 Gas Model Wiring Diagram

Typical Diagram For Club Car DS Gas 1998-2011
Typical Diagram For Club Car DS Gas 1998-2011
Electrical Component Box (Under Driver Side Seat)
Electrical Component Box (Under Driver Side Seat)
Club Car Forward/Reverse Assembly (Gas Model)
Club Car Forward/Reverse Assembly (Gas Model)

Troubleshooting Guide For Club Car DS Gas Models

SYMPTOMPOSSIBLE CAUSES
ENGINE IS HARD STARTING1. Spark plug partially fouled or in poor condition.
2. Spark plug wire damaged.
3. Loose wire connection at the CDI unit.
4. CDI unit failed.
5. Low cylinder compression.
6. Water or dirt in the fuel system and/or carburetor. Dirty or clogged fuel filters.
7. Carburetor improperly adjusted.
8. Starter-generator belt slipping.
ENGINE STARTS BUT RUNS IRREGULARLY OR MISSES1. Spark plug partially fouled or in poor condition.
2. Spark plug wire damaged.
3. CDI unit failed.
4. Water or dirt in the carburetor.
5. Water or dirt in the fuel system or dirty or clogged fuel filter.
6. Fuel pump malfunction, fuel pressure to engine too low.
7. Carburetor float adjustment incorrect.
ENGINE TURNS BUT FAILS TO START1. Gasoline tank empty.
2. Gasoline line or filters clogged.
3. Fouled spark plug.
4. Spark plug wire damaged.
5. Loose wire connection at CDI.
6. CDI unit failed.
7. Engine flooded with gasoline as a result of over choking.
8. Kill circuit grounded.
9. Fuel pump malfunction or failure.
ENGINE OVERHEATS1. Fan screen partially blocked or plugged.
2. Incorrect governor adjustment.
ENGINE PRE-IGNITES1. Excessive carbon deposit on the piston head, or in the combustion chamber.
2. Spark plug heat range is incorrect for the engine.
3. Unsuitable or contaminated fuel.
ENGINE HAS LOSS OF POWER1. Exhaust valve restricted with carbon deposit.
2. Muffler or exhaust pipe plugged with carbon or other restriction.
3. CDI unit failed.
4. Air filter dirty or clogged.
5. Governor improperly adjusted.
6. Throttle linkage out of adjustment.
7. Spark plug failed.
8. Restricted fuel flow.
9. Torque converter not backshifting properly.
SPARK PLUG FOULS REPEATEDLY1. Incorrect plug.
2. Spark plug wire damaged.
3. Unsuitable gasoline or incorrect (rich) fuel mixture.
4. CDI unit failed.
5. Dirt entry.
CARBURETOR FLOODS1. Inlet valve or seat leaking, dirty, worn, or damaged.
2. Float damaged and filled with gasoline.
3. Incorrect float level setting.
STARTER FAILS TO OPERATE1. Neutral lock-out cam is in the wrong position.
2. Fuse blown.
3. Battery dead.
4. Starting control circuit not operating.
5. Starter-generator failed.
6. Starter solenoid failed.
7. Accelerator micro switch failed.
8. Key Switch failed.
9. Neutral lock-out micro switch failed.
STARTER-GENERATOR DOES NOT CHARGE BATTERY1. Loose or broken wire in starter-generator circ1 it.
2. Generator field coil shorted.
3. Brushes worn or commutator dirty.
4. Loose or slipping starter-generator belt.
5. Voltage regulator failed.
6. Battery failed.
TRANSMISSION DOES NOT ENGAGE OR DISENGAGE SMOOTHLY1. Transmission shifter linkage binding or out of adjustment.
2. Insufficient (low) level of lubricant in transmission or wrong type of lubricant in transmission.
3. Internal gears damaged or worn.
4. Synchronizer rings worn or damaged.
ENGINE WON'T QUIT RUNNING1. Kill circuit wire is disconnected from CDI.

Recent Content