How to Convert a 36-V Electric Golf Cart to 48-V Without Burning the Motor

Meta description: Step-by-step guide, wiring diagram and cost spreadsheet for a safe 36→48-V conversion that adds 8 km/h top speed and 21 % more torque to your electric golf cart.

Tools & parts checklist
– 48-V 5.5-kW separately-excited motor (plug-and-play spline)
– 48-V 400-A controller with regen braking
– 6×8-V AGM → 4×12-V lithium drop-in or 16×3.2-V LiFePO₄ cells
– 4-Gauge welding cable & hydraulic crimper
– Digital dash voltage converter (12-V accessory line)

Phase 1 – bench-test
Lift the rear axle, secure the electric golf cart on jack-stands, and test new controller with old motor at 36 V; confirm Hall-sensor alignment.

Phase 2 – swap & wire
Label every 6-gauge run, install motor, re-route controller B+ through 400-A fuse, mount emergency disconnect within 30 cm of battery pack.

Phase 3 – reprogram
Use handheld programmer to set 19 km/h top speed, 230-A max battery draw, 12 km/h reverse limit. Test uphill for 15 min; motor temp ≤65 °C.

Budget & payback
Parts $1 050 + 4 h labour. Gain 8 km/h, 21 % hill torque, 14 % range. Rental fleets recoup cost in 7 months via premium “performance cart” upsell.