Specifications

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We would like to thank you for purchasing our exclusive Motor & Controller Performance Enhancement

Kit. We take great pride in our products and feel certain that this kit will offer you many years of trouble-

free service. We ask that you take a moment to read these instructions completely before beginning your

installation. Familiarity with the parts and an understanding of the procedures will ensure that your installation

goes smoothly and safely. Additionally, it will give you an opportunity to determine if your cart might have

any damaged, corroded, or missing parts, which will need replacing prior to using your new Performance

Enhancement Kit.

ABOUT THIS PERFORMANCE ENHANCEMENT KIT

This Performance Enhancement Kit is designed speciﬁcally for 1994.5-Present EZGO Non-DCS 36 and 48

volt electric golf carts. If you are unsure of your golf cart type, please see our catalog or contact our technical

department, toll free at 1-888-444-9994, or online at www.buggiesunlimited.com. During the installation of this

kit you will be upgrading three major electrical components from your golf cart, with three high performance

components in our STQ EZ9 2001 Performance Enhancement Kit. These parts are: the motor, the speed

controller, and the solenoid. All of your electrical connections will be made between these components and

either the battery group or a device called a forward/reverse switch. You should allow about 4 hours for

installation.

PARTS INCLUDED IN OUR KIT

1) Electric motor (per application).

2) 500 amp speed controller 36/48 volt.

3) Electric solenoid (36/48 V high performance).

4) 4 Gauge Cable Kit (Non-DCS), including:

a) 3 red coded cables.

b) 1 blue coded cable.

c) 1 white coded cable.

d) 1 orange coded cable.

e) 1 green coded cable.

f) 1 black coded cable.

g) 5 red/black coded cables.

5) Bridge Resistor (250 ohm) and diode.

6) Hardware kit.

7) 2 Contacts, F&R Switch

STQ EZ9 2001 PERFORMANCE ENHANCEMENT KIT

For EZGO NON-DCS Installation Instructions

Contacts

Summary of content (14 pages)

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STQ EZ9 2001 PERFORMANCE ENHANCEMENT KIT For EZGO NON-DCS Installation Instructions We would like to thank you for purchasing our exclusive Motor & Controller Performance Enhancement Kit. We take great pride in our products and feel certain that this kit will offer you many years of troublefree service. We ask that you take a moment to read these instructions completely before beginning your installation.
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TOOLS AND MATERIALS REQUIRED TO INSTALL KIT 1) SAE socket set, with ratchet and 3” and 6” extensions. 2) 8mm deep socket 3) SAE combination wrench set. 4) 1/2” wrench (extra). 5) #2 Phillips and Flat Tip screwdrivers. 6) Wire cutters. 7) T15 Torx driver. 8) Heavy weight grease. 9) Wire Terminal Crimper 10) Safety Goggles/Glasses ADDITIONAL TOOLS WHICH MAKE THE JOB BETTER AND FASTER 1) 2) 3) 4) 5) Battery Carrying Strap. Part # BT8001. Battery Terminal Protector Spray. Part # BT60512.
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INSTALLATION 1) SEAT CUSHION REMOVAL: Remove the seat assembly by lifting the side grab handles. The cushion hinges to the front of the cart, and will simply lift off when it’s in the vertical position. 2) ACCESS PANEL REMOVAL: Remove the black plastic rear access panel located behind the seat, which is secured using ﬁve T15 Torx head screws. 1 3) BATTERY REMOVAL: There are two things to take note of here: Battery placement and wiring layout. NOTE: Battery acid can be very damaging...
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) SPEED CONTROLLER AND SOLENOID REMOVAL: Directly below the passenger’s seat you will ﬁnd a black plastic cover… this is called the controller cover. The cover is secured using four hex head machine bolts. Remove these bolts using a 3/8” socket with the appropriate extension. Underneath the cover you will notice the speed controller and the solenoid. The speed controller is the small metal box and the solenoid is the cylindrical device mounted on top of the controller.
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) FORWARD/REVERSE SWITCH WIRE REMOVAL: Locate the forward/reverse switch assembly, which is found directly in front of the speed controller mounting area. Remove all four heavy gauge cables from the switch assembly and retain the factory hardware for reinstallation of your new cables. See the wiring diagram (pg. 12) for a visual representation of the forward/reverse switch assembly.
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8) COMPONENT INSTALLATION PREPARATION: Before installing our Performance Enhancement Kit in your cart, take a little time to clean the areas now exposed by the removed components. The motor mount may have some grit or dirt around the opening of the mount. A moist rag or small brush can be used to clean that area. Avoid letting dirt fall into the housing. The battery trays may have dirt, leaves, or corrosion, which should be cleaned. For instruction on cleaning corrosion, see step 12.
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b) c) d) e) f) each end. This wire will jumper across the two large threaded lugs of the solenoid. Recall that the solenoid is one of the components which will have the double nuts installed on the lugs. Ensure that the bottom nut is threaded onto each of the two large lugs, and then install the wire by placing one ring terminal over each large threaded lug. It may be necessary to bend the wire slightly to make it ﬁt… this is normal. Locate the red coded cable that is 27” long.
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g) Locate the green coded cable that is 27” long and connect one end of this cable to the electric buss bar marked “M-” on the controller. Tighten the provided nut and bolt securely using 1/2” wrenches. Remember to use the opposing wrench technique and avoid twisting or bending the buss bar. Using a 1/2” wrench and the factory hardware, connect the other end of this cable to position “A” of the forward/reverse switch assembly, as shown on the wiring diagram (pg. 12).
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and warm soapy water. Residual corrosion and acid spillover can be removed with a baking soda and water mixture using one small box of soda to one gallon of water. Remember, Battery Strap battery acid can be very damaging… wear rubber gloves, eye protection, and old clothes. Work in a well-ventilated and appropriate area for the task. Battery residue can stain concrete.
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f) g) Connect the six pin Molex connector to the corresponding controller five pins. Make sure of proper alignment while pushing the connector on. Tech Tip: notice in figure 11a a component marked as “diode connection”. This diode is connected across the small solenoid terminals. It is of utmost importance to make the small activation wires connect to the proper terminals. For the correct connection make sure you connect the positive input wire to the diode end marked with the white band.
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1) 2) 3) 4) Ensure that the steering wheel is centered and the front wheels are pointed straight ahead. Ensure that other people are not standing in front of or behind the cart during testing. Place the cart in neutral and ensure that the parking brake is OFF. With your left foot “over” the brake pedal, and your right foot OFF the throttle pedal… turn the key switch on. Be prepared to apply the brake and turn the key off simultaneously, if the cart should move… it should NOT move.
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SCP EZ BRS F&R SWITCH UPGRADE KIT Used on EZ-GO Electric Carts INSTALLATION Before beginning lay out all the parts in an organized manner, this will make the install much easier. CAUTION: Disconnect the main positive and negative battery connections. Wear the appropriate eye protection and be aware that the high voltage system you are working with can cause severe burns, be very careful to not short out any tools on the battery connections.
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2 3 1 Fuse 4 5 Battery Pack MS2 6 Solenoid Controller MS4 S2 A1 S1 A2 Forward & Reverse Failure to connect power cables correctly will void warranties. Solenoids vary in shape and size, the connections remain the same.