Yamaha Controller Upgrade

All D&D golf cart motors work on 36V and 48V golf carts. After converting a golf cart from 36V to 48V the performance gain from a standard EZGO, Club Car, or Yamaha model is normally around 3-4mph. For 72V and other voltages, give us a call.

Please follow the slides to determine if your cart is Regen or Series. For security to be certain, confirm with at least 3 methods: Check for Tow/Run switch (Regen), Speed sensor presence (Regen), Shunt/Round field coil (Regen), or 2 small + 2 large terminal bolts (Regen). You can also contact us at 315-701-0635 for assistance.

You will need to cut off the connector at the end of the speed sensor on the D&D motor and strip the 3 wires. The wires on the D&D motor are Red, Green, and Black. Strip the insulation from the 3 wires coming from the vehicle connector. Once this is done, twist together all wires with matching colors (ex. Red motor speed sensor wire with Red golf cart wire) and cover the exposed wire with electrical tape. If there is one mismatching wire color on the motor and golf cart, connect those two together, those will be your ground wires.

We recommend buying "PB Blaster Penetrant" to loosen up any corrosion or other issues stopping the motor from disconnecting. This can be purchased for about $10 from Home Depot. Once purchased, spray liberally on the drive end head and mounting bolts of the old motor and wait 8 hours before attempting to remove the motor again.

Golf cart batteries are either 6 volt, 8 volt, or 12 volt. You can tell the voltage based on how many water holes your battery has on the top. Multiply your battery voltage by the number of batteries in your golf cart to find your golf cart voltage.

• 3 holes = 6 volts
• 4 holes = 8 volts
• 6 holes = 12 volts

The "Choose a Motor Tool" accounts for shaft type and mounting pattern when providing motor options. Mounting pattern and shaft are unique for each golf cart brand, so we recommend customers use the Choose a Motor Tool to provide a good buying experience and correct motor options.

This sometimes occurs when installing a D&D motor to replace an older motor. To fix this, swap the motor connections on the A1 and A2 terminals.

You need to purchase batteries that have a maximum discharge of 500 amps. The type of battery (Lithium, Lead-Acid, etc.) is independent of Max Discharge. Navigate to our "Beginners Guide to Motors" for more details about batteries.

No. D&D motors use higher quality shafts made in the USA. This allows our motors to run quietly without an additional rubber insert.

Upgrading a V-Glide controller to a solid state controller will take a few hours and can be a bit complex, but it will increase your max controller amps from 200 to the max amps of the new controller (up to 600 amps). Your performance will increase significantly. We recommend following our youtube video walkthrough explaining exactly how to do this process.

There are a multitude of reasons behind buying new high performance golf cart motors over 3rd party ones. Mainly when it comes to better performance, reliability, greater efficiency, longer lifespan, and most importantly how customizable it is. A newer motor can be sorted out and customized to what you need for your vehicle setup, performance, and application.

A DC motor is an electric motor that runs on direct current (DC) electricity. DC motors can operate directly from rechargeable batteries, providing the motive power for electric vehicles. The brushed DC electric motor generates torque directly from DC power supplied to the motor by using internal commutation, stationary magnets, and rotating electrical magnets. Advantages include low initial cost, high reliability, and simple control of motor speed.

The shunt motor is different from the series motor in that the field winding is connected in parallel with the armature instead of in series. The shunt winding is made of small-gauge wire with many turns. Since the shunt field coil is made of fine wire, it has very low starting torque but excellent speed control. The speed can be controlled by varying the amount of current supplied to the shunt field or controlling the current to the armature.

In a series motor, the field winding is connected in series with the armature winding. This motor provides high starting torque and is able to move very large shaft loads when first energized. The field is made from heavy-gauge wire that can carry large amounts of current. Series motors are ideal for applications requiring high starting torque like hoists, cranes, and starter motors.

Series Motors: High starting torque, simple design, self-regulating speed, low cost. However, poor speed regulation, runaway risk, limited reversibility.

SEPEX Motors: Excellent speed control, stable operation under load, easier reversibility, better efficiency at variable loads. However, more complex and costly, lower starting torque, additional control components needed.

The electric DC motor has two basic parts: the rotating armature and the stationary field coils (stator). The armature is made of coils of wire wrapped around the core with an extended shaft that rotates on bearings. The ends of each coil terminate at the commutator where brushes make electrical contact. When voltage is applied, current flows through the field and armature windings creating magnetic fields that cause the armature to rotate through magnetic attraction and repulsion.

There are several ways to make your golf cart faster: upgrade to a high speed golf cart motor, upgrade to a high speed controller, increase the diameter of your tires, increase the voltage from 36V to 48V, or increase the gearing of your cart. Each method has different benefits and considerations for performance improvement.

Upgrading to a high speed motor is one of the most effective ways to increase your golf cart's speed. High speed motors are designed to operate at higher RPMs while maintaining torque and efficiency. This upgrade typically provides the most significant speed improvement compared to other modifications.

A high speed controller can increase your cart's performance by providing more current to the motor and better speed regulation. Modern controllers offer programmable features, regenerative braking, and improved efficiency. When paired with a high performance motor, a quality controller maximizes your speed and performance gains.

Increasing tire diameter effectively increases your golf cart's top speed by covering more ground per revolution. However, this modification may reduce acceleration and torque, especially on hills. It's important to balance tire size with your motor's capabilities to avoid overloading the system.

Converting from 36V to 48V typically increases speed by 3-4 mph and improves overall performance. This requires replacing your battery pack and ensuring your motor and controller are compatible with 48V operation. The voltage increase provides more power to the motor for better acceleration and hill climbing.

Changing the gear ratio in your differential or using different motor mounting can alter your cart's speed characteristics. Lower gear ratios increase top speed but reduce torque, while higher ratios improve acceleration and climbing ability but limit top speed. This modification requires mechanical expertise and may affect other performance aspects.

Speed control in a DC motor can be achieved through several methods: varying the armature voltage, controlling the field current, or using pulse width modulation (PWM). Modern electronic controllers use PWM to efficiently control motor speed by rapidly switching the power on and off, providing smooth speed control and improved efficiency.

Electric Motors: Quiet operation, instant torque, low maintenance, environmentally friendly, lower operating costs. However, limited range, charging time required.

Gas Motors: Longer range, quick refueling, higher top speeds possible. However, louder operation, more maintenance required, emissions, higher operating costs.

To test for a short in your golf cart motor: 1) Disconnect all wiring, 2) Use an ohmmeter to test resistance between terminals, 3) Test each terminal to the motor frame/ground, 4) Check for continuity in windings, 5) Look for burned or damaged wiring. Very low resistance readings or connections to ground indicate a short circuit that requires motor repair or replacement.

4 AWG wire kits are designed for high-current golf cart applications. These kits typically include appropriately sized cables for battery connections, motor connections, and controller wiring. The 4 AWG wire can handle the high current demands of golf cart motors while minimizing voltage drop and ensuring safe, reliable operation.

There are quite a few things to you can do to increase the efficiency of a DC motor. Here are a few of them:

Maintenance: Regular inspections, lubrication, and the cleanness of your motor can all have an impact. Always make sure your motor is as clean as possible and that its components don't have too much wear and tear. This includes things such as its brushes and commutators, as well as electrical connections and insulation.

Temperature management: The name of the game is keeping cool. High heats can cause damage to your motor. The key to keeping a motor cool is to choose a motor with enough steel and copper. This can be done by using our "Choose a Motor Tool". If possible we recommend using ventilation, internal or external fans, or a heatsink.

High Quality Components: Look for high quality copper windings, bearings, and lubricants. As well as high quality electrical steel in the laminations with minimal core loss.

Keep the rotor and stator close together: Precision is key, keeping a small gap between the rotor and stator without letting them touch can increase efficiency.

We understand sometimes you need to dive into the finer details. Disassembling a golf cart axle can be tricky, but we're here to help. Follow the step-by-step guide below:

Tools you'll need:
• Wheel Chocks
• Car Jacks
• Jack Stands
• Socket Set
• Ratchet
• Needle-Nose Pliers
• Bearing Puller

Steps:
1. Park the golf cart on a flat surface. Place wheel chocks in front of the front wheels. Jack up the rear end and set jack stands underneath.
2. Remove the bolts holding the rim onto the hub and pull off the tire and rim.
3. Take off the cover of the drum brake and remove the bolts securing it to the hub.
4. Use needle-nose pliers to pull out the "C" clip through the hole in the flange. Pull the hub away from the axle.
5. Attach the bearing puller to the center of the axle and secure its arms around the rear bearing housing. Tighten until the bearing comes free.
6. Finally, pull the axle out of the golf cart by hand.

1. Unplug the positive and negative connections from the battery pack
2. Put the cart to reverse
3. Push the accelerator pedal fully down until the reverse buzzer ceases
4. Reconnect the power supply

Ensure that the cart is not in sleep mode. You can do this by driving the cart a short distance. With the F&R switch set to any of the three positions and the Tow/Run switch in the Run position, manually push the cart to simulate a roll-away situation. The "Roll-Away" braking system will engage to slow the cart down and prevent it from rolling away, accompanied by a series of beeps from the reverse buzzer as it decelerates. If the cart rolls freely without any resistance, this indicates a lack of communication between the cart's speed sensor and the controller. In this case, there is a speed sensor failure, and it will need to be replaced.

The issue with a non-running diagnosis lies in identifying the cause versus the effect. The root of the issue is often the motor. A motor that is shorted, even partially, can lead to controller failure. Installing a new controller with a faulty motor will likely cause another failure.

Testing a Regen/Shunt-Wound Motor:
1. Discharge the controller circuit
2. Disconnect F1 and F2 from the controller
3. Disconnect all cables from the motor
4. Use an ohmmeter to test:
- A1 to A2: Any reading other than "open" is acceptable
- F1 to F2: Reading between 1 and 3 ohms is acceptable
- Any continuity from studs to case indicates a problem
5. Remove the motor to inspect windings and brushes

Even if the motor passes all tests, it may still be defective. If it fails any test, it's likely shorted and will damage a new controller.

On a typical solenoid there are four terminals - usually two large and two small. Battery voltage is applied to the two small terminals to activate the solenoid which connects the two large terminals together.

Testing Steps:
1. Disconnect cables from the two large terminals and wrap cable ends in tape
2. Set voltmeter to OHMS and place probes on each large terminal
3. With key off and cart in neutral, there should be no reading
4. Put cart in forward, key on, step on accelerator - you should hear a click
5. If you hear a click, test resistance between large terminals - should read 0 to 0.4 ohms
6. If no click, test voltage between small terminals with key on, cart in forward, accelerator pressed - should see full battery voltage

If you see full battery voltage but no click, the solenoid coil has failed. If meter reads 0, there's a problem elsewhere in the cart.

A Golf Cart Solenoid is nothing more than a switch activated by external electrical input. It has two basic circuits: Primary (activation circuit) and Secondary (power circuit).

Testing Process:
A) Does the solenoid make a "clicking" sound?
If not, check if activation voltage is present at small terminals. Connect voltmeter across connections and activate the system (run mode, key on, forward, accelerator pressed). If you read system voltage but no click, the solenoid is defective.

B) No click and no system voltage:
This means one voltage potential is missing. Test each potential separately to determine which is missing - could be key switch, micro switches, wiring, or ground connection.

Secondary Circuit Testing:
If solenoid clicks but cart won't run, disconnect cable from load terminal and test for voltage. No voltage indicates defective contacts; voltage present means the problem is in controller, motor, or wiring.

Follow systematic troubleshooting based on symptoms:

Safety First:
• Raise rear wheels off ground with proper support
• Disconnect battery when required
• Use caution with higher voltage carts
• Work in well-ventilated area
• Keep flames away from battery compartment

Common Issues:
• If solenoid doesn't click: Check activation voltage at small terminals
• If clicks but cart doesn't run: Test secondary circuit for voltage
• If cart runs constantly: Check for stuck contacts
• If missing voltage: Trace through key switch, micro switches, and wiring

Remember to use correct wiring diagram for your specific cart make, model, and year. Some systems use different voltage configurations or grounding methods.

Electric golf carts normally run on a bank of six batteries. The batteries are wired in series to provide the correct voltage.

Steps:
1. Open battery compartment by lifting the seat
2. Remove black negative cable first, then positive wire from each battery (front to rear order)
3. Lift out batteries requiring replacement (remove securing brackets if needed)
4. Place new batteries in same positions and re-secure brackets
5. Reconnect cables: Main positive lead connects to first battery positive terminal
6. Connect cable from first battery negative to second battery positive
7. Continue connecting negative to positive until all batteries are connected
8. Last battery negative connects to frame/golf cart controls
9. Connect reverse positive cable to any positive terminal on the battery bank

This series wiring provides sustained charge for propulsion throughout a playing day.

Regular upgrades to your D&D Motor Systems motor can drastically improve the results of your cart. Proper maintenance includes regular inspections, keeping components clean, proper lubrication, and ensuring all electrical connections are secure.

Caused by dirt in brake cable housings, dust or oil on brake shoes, affecting brake release. Clean cable housings and brake components, replace oil-contaminated brake shoes as needed.

Wheels should have 1/4-inch toe-in; the distance from the front should be slightly shorter than the back to ensure proper alignment. Adjust tie rods to achieve proper alignment.

Batteries need the correct water level (1/4 inch above plates) and should be checked with a load tester to ensure consistent performance across all batteries. Replace weak batteries to maintain proper cart performance.

Corroded or worn battery cables should be cleaned or replaced, as they can disrupt battery function. Ensure all connections are tight and free of corrosion.

Clean or replace the F&R switch if contacts are dirty, as it can affect performance. Dirty contacts can cause intermittent operation or poor connection.

Ensure the V-glide wiper brush reaches its full range when the accelerator is pressed and is level on contact pads. Proper adjustment is critical for smooth operation.

Bearings should be clean and well-greased without overtightening to avoid wheel drag. Overtightened bearings can cause excessive friction and reduce performance.

Oil leaks onto brake shoes can cause dragging; replace seals and clean or replace shoes as needed. Leaking seals can contaminate brake components and cause performance issues.

Underinflated tires (run at 25 psi) can reduce cart speed, so keeping proper tire pressure is essential. Check tire pressure regularly and maintain recommended PSI.

Lack of airflow can cause motor overheating, leading to insulation breakdown; adequate airflow keeps it cool. Ensure ventilation is not blocked and motor housing is clean.

Worn bearings can cause armature drag, leading to excess noise and reduced performance. Replace worn bearings to restore smooth motor operation.