Last Updated on August 25, 2023 by Chuck Wilson
Club Car Golf carts have undergone numerous transformations since 1975, and while the fundamental electrical design has remained relatively unchanged, there are minor differences. These distinctions are crucial when it comes to troubleshooting your cart.
I have taken all the old Club Car wiring diagrams standards and redrawn them to be easily read so you can trace out any faulty wiring on your cart with minimum effort. Enjoy!
- Disconnect the Battery: Always do this before working on any electrical system. This will prevent any accidental shorts or shocks.
- Identify the Problem: If you haven’t already, identify where the problem is occurring. Check if any systems are not working correctly. For example, if the headlights aren’t working, the problem is likely in the wiring to the headlights.
- Refer to the Diagram: Refer to the wiring diagram for your specific model of Club Car. This will show you the correct path for all the wiring and which color wires go to each component.
- Trace the Wiring: Starting at the source (the battery), follow the wiring to the component that isn’t working. Look for any obvious signs of damage like cuts, frays, or burns. Also, check for any loose connections.
- Test the Wiring: If you have a multimeter, you can test the wiring for continuity. This will tell you if there is a break in the wire that isn’t visible.
- Repair or Replace: If you find a faulty wire, you can either repair it or replace it. If it’s a simple cut or fray, electrical tape may be enough to fix it. If it’s severely damaged or burnt, you’ll need to replace the entire wire.
Remember, always refer to the specific wiring diagram for your model and year of Club Car. If you’re unsure about anything, it’s always best to consult with a professional.
Table of Contents
Club Car DS Electric Models
Club Car Wiring Diagrams DS 1981-85 Electric Golf Cart 5 Solenoid Type
Club Car DS 1986-94 Electric 5 Solenoid Type Wiring Diagram
Remember that working with wiring and electrical components can be dangerous if not done correctly. If you’re not comfortable or experienced with this kind of work, it’s best to hire a professional.
Club Car DS 1995-2002 Electric 36 Volt V-Glide External Resistor Type Wiring Diagram
Troubleshooting Guide For Club Car DS Electric Models
| SYMPTOM | PROBLEM AREAS | POSSIBLE CAUSES |
|---|---|---|
| Vehicle will not run - no "solenoid click" | Batteries | 1. Battery connections 2. Discharged batteries |
| Key Switch | 1, Loose wires 2. Failed switch |
|
| Forward/Reverse Anti-Arcing Micro Switch | 1. Loose Wires 2. Failed Switch 3. Cam not Activating Micro Switch |
|
| Accelerator Linkage | 1. Accelerator rod disconnected or loose | |
| Speed Controller Micro Switch | 1. Loose wire 2. Disconnected or loose wires 3. Failed switch |
|
| Solenoid | 1. Loose Wires 2. Failed solenoid coil |
|
| Vehicle will not run - "solenoid clicks" | Forward/Reverse Switch | 1. Loose wires 2. Failed contacts |
| Motor | 1. Loose wires 2. Open windings 3. Worn out brushes |
|
| Solenoid | 1. Failed contacts | |
| Cart Skips One Or More Speeds | Speed Controller | 1. Loose or broken connections 2. Brush or contacts corroded, burned, or worn 3. Incorrect wiring |
| Resistors | 1. Loose or broken resistor | |
| Cart Runs Slow | Speed Controller | 1. Loose or broken connections 2. Contacts corroded, burned, or worn |
| Batteries | 1. Loose or corroded terminals 2. Incorrect wiring 3. Battery failure 4. Batteries not fully charged |
|
| Accelerator Linkage | 1. Improper adjustment on accelerator rod | |
| Motor | Loose cables 2. Brushes worn or misaligned 3, Dirty commutator |
|
| Brakes | 1. Brakes dragging | |
| Tires | 1. Flat or underinflated tires | |
| Cart runs in first speed when F&R switch is in forward or reverse with key switched off | Solenoid | 1. Solenoid contacts welded in closed position |
| Accelerator Linkage | 1. Misadjusted or bent accelerator rod | |
| Speed Controller | 1. Pedal misadjusted 2. Stuck accelerator brush |
|
| Cart goes forward but not in reverse - or cart goes in revers and not forward | Forward/Reverse Anti-Arcing Micro Switch | 1. Loose or broken wires 2. Switch not actuating properly |
| Forward/Reverse Switch | 1. suspect continuity of switch contacts | |
| Cart not charging completely | Charger Connections | 1. Loose wires at F/R Switch, receptacle, or battery |
| 1. Charger plug not fully engaged with receptacle | ||
| On Board Fuse | 1. Blown fuse | |
| Charger | 1. 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 Wiring Diagram DS 1984-1985 Gas Model
There was a small change in the Limit Switch Wiring for later models of the same year.
Club Car DS 1986-1990 Gas Model Wiring Diagram
Club Car DS 1991 – 1997 Gas Model Wiring Diagram
Club Car DS 1998 – 2011 Gas Model Wiring Diagram
A replacement for this F/R switch available on Amazon
Troubleshooting Guide For Club Car DS Gas Models
| SYMPTOM | POSSIBLE CAUSES |
|---|---|
| ENGINE IS HARD STARTING | 1. 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 MISSES | 1. 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 START | 1. 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 OVERHEATS | 1. Fan screen partially blocked or plugged. 2. Incorrect governor adjustment. |
| ENGINE PRE-IGNITES | 1. 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 POWER | 1. 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 REPEATEDLY | 1. Incorrect plug. 2. Spark plug wire damaged. 3. Unsuitable gasoline or incorrect (rich) fuel mixture. 4. CDI unit failed. 5. Dirt entry. |
| CARBURETOR FLOODS | 1. Inlet valve or seat leaking, dirty, worn, or damaged. 2. Float damaged and filled with gasoline. 3. Incorrect float level setting. |
| STARTER FAILS TO OPERATE | 1. 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 BATTERY | 1. 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 SMOOTHLY | 1. 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 RUNNING | 1. Kill circuit wire is disconnected from CDI. |
