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cart as we started the wire cleanup.JPG | Hits: 382 | Size: 65.71 KB | Posted on: 7/10/08 | Link to this image
I poped the cover and saw a wiring mess. i needed to charge the battery and add a new protected light power and a new horn circuit.this is how she looked when i started.
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negitive wire as i started.JPG | Hits: 366 | Size: 61.5 KB | Posted on: 7/10/08 | Link to this image
i start with the negitive side first. the battery connector was corroded and the wire in poor condition.
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old negitive wire.JPG | Hits: 384 | Size: 53.25 KB | Posted on: 7/10/08 | Link to this image
I removed the negitive wire from the battery and the solinoid pack. I was surprised there was nothing to the frame. i might add a frame ground soon.
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new battery connector.JPG | Hits: 412 | Size: 50.93 KB | Posted on: 7/10/08 | Link to this image
I got new marine battery connectors. these were not to bad price and allowed a fast connection.
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negitive wire 3.JPG | Hits: 383 | Size: 49.28 KB | Posted on: 7/10/08 | Link to this image
this was an off the shelf negitive cable. it was 15" it has loops on both ends.
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negitive wire 4.JPG | Hits: 379 | Size: 50.91 KB | Posted on: 7/10/08 | Link to this image
I put the new battery connector in place. i used a socket and tapped it home with a hammer.
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negitive wire 02.JPG | Hits: 420 | Size: 50.34 KB | Posted on: 7/10/08 | Link to this image
I masked off the threads and sprayed the connector with battery sealer.
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new negitive wire.JPG | Hits: 460 | Size: 58.72 KB | Posted on: 7/10/08 | Link to this image
I ran the new negitive wire the same way the old one went. this looks alot better. i had to wait 3 days to get the new POS cables, but just this made the cart run better.
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POS wire cleanup.JPG | Hits: 560 | Size: 48.06 KB | Posted on: 7/10/08 | Link to this image
I got the new POS wires in and now time to swap. here it is as i started.
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POS wire cleanup 02.JPG | Hits: 400 | Size: 62.38 KB | Posted on: 7/10/08 | Link to this image
The connector almost rotted off. i found a power line to the lights and a red with white stripe wire. time to remove all the other battery taps to a power take off.
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POS wire cleanup 03.JPG | Hits: 370 | Size: 42.38 KB | Posted on: 7/10/08 | Link to this image
Here are the 2 new POS cables. one to the started / generator and the other to the new power take off.
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POS wire cleanup 04.JPG | Hits: 360 | Size: 46.3 KB | Posted on: 7/10/08 | Link to this image
I cleaned the battery post and installed the new connector. i I got lucky and had some red with white stripe wire in my box. i cut back the old red wire to good wire and soldered and heat shrinked the joint. I routed the new red wire along the stock wire loom.
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POS wire cleanup 05.JPG | Hits: 366 | Size: 55.7 KB | Posted on: 7/10/08 | Link to this image
If you look closely you can see the red heat shrink and the new wire.
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here is the re-routed red wire
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power tap placement.JPG | Hits: 371 | Size: 49.71 KB | Posted on: 7/10/08 | Link to this image
I get these power taps from chevy trucks and suburbans at the junk yard. i needed to find a spot that was out of the way and flat and large enough to hold the tap. this space looked good to me it was perfect.
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I marked the spot and drilled a couple holes---making sure it was clear under the cover and do not drill the wheel.....
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I used a couple bolts and washers and lock washers to hold the tap in place.
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POS wire cleanup 06.JPG | Hits: 388 | Size: 59.51 KB | Posted on: 7/10/08 | Link to this image
I added a loop connector to the red/white wire and added it to the power tap.
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POS wire cleanup 07.JPG | Hits: 361 | Size: 67.11 KB | Posted on: 7/10/08 | Link to this image
Time to feed the power tap.
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POS wire cleanup 08.JPG | Hits: 363 | Size: 58.69 KB | Posted on: 7/10/08 | Link to this image
Here is the new wire connected to power tap. this is alittle over kill but i did not want to have a short.
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POS wire cleanup 11.JPG | Hits: 380 | Size: 56.87 KB | Posted on: 7/10/08 | Link to this image
i was going to run a mini fuse at the power tap for each line. i found this cool fuse block and decided to use it. here is the power for it. all soldered and heat shrinked.
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POS wire cleanup 10.JPG | Hits: 399 | Size: 61.92 KB | Posted on: 7/10/08 | Link to this image
here is the fuse holder and the main power tap.
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POS wire cleanup 09.JPG | Hits: 378 | Size: 57.62 KB | Posted on: 7/10/08 | Link to this image
here is a close up of the fuse box it hold 4 circuits. i drilled and bolted it to the wheel well like the power tap. this was taken before i ran the main wire.
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