# 2002 Gem electrical issues **URL:** \ **Category:** GEM Forum\ **Created:** [February 8, 2025, 9:55pm UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852 "2025-02-08T21:55:35Z")\ **Posts on this page:** 7\ **Page:** 1
**Author:** ![Dday](https://avatars.discourse-cdn.com/v4/letter/d/e480ec/32.png) [@Dday](https://community.electricforum.com/u/Dday)\ **Post date:** [February 8, 2025, 9:55pm UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/1 "2025-02-08T21:55:35Z")
Maybe someone can help me. My neighbors just bought a 2002 gem with lithium batteries. Upon further review it has a blue motor 7.5 horsepowe and Has a battery evo lithium setup. At first the cart ran well. Easily drove at 40 mph. After driving a couple miles it smelt like burning. The positive cable between the distribution block and dc to dc converter got really hot. It melted part of the distribution block mounted to the front of cart. Why would get so hot? Does the cart need to be reprogrammed? Any help would be appreciated. Thanks in advance. ---
**Author:** ![AssyRequired](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/assyrequired/32/7621_2.png) [@AssyRequired](https://community.electricforum.com/u/AssyRequired)\ **Post date:** [February 8, 2025, 10:20pm UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/2 "2025-02-08T22:20:38Z")
An overheated connection point is always due to a bad connector in some way. It was probably loose but also dirty when assembled, or sometimes a bad/failing crimp. These can get hot enough to melt the lead off battery posts. Even something like this is NOT a good connection. ![dirtyterm](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/7/71a0947759d80e0b6b22ce2364270291ceae67e2.jpeg) ![A1 terminal melted](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/3X/f/e/febdde016745b6423f456d49cbb0f3a0b603e03c.jpeg) ---
**Author:** ![Dday](https://avatars.discourse-cdn.com/v4/letter/d/e480ec/32.png) [@Dday](https://community.electricforum.com/u/Dday)\ **Post date:** [February 8, 2025, 11:54pm UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/3 "2025-02-08T23:54:51Z")
Ok very helpful. I’ll try that and see if it helps. ---
**Author:** ![Dday](https://avatars.discourse-cdn.com/v4/letter/d/e480ec/32.png) [@Dday](https://community.electricforum.com/u/Dday)\ **Post date:** [February 9, 2025, 1:51am UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/4 "2025-02-09T01:51:55Z")
After I looked closer. The cable had a washer between the bus bar and terminal. Never thought a washer between the two could cause that. Thanks again for the suggestion. ---
**Author:** ![JarJarJava](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jarjarjava/32/15158_2.png) [@JarJarJava](https://community.electricforum.com/u/JarJarJava)\ **Post date:** [February 9, 2025, 2:38am UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/5 "2025-02-09T02:38:12Z")
> [@Dday](#): > > The positive cable between the distribution block and dc to dc converter got really hot. It melted part of the distribution block mounted to the front of cart. > Why would get so hot? The cart is trying to tell you something. Something important. Its jumping right to step 3. You should oblige it. ---
**Author:** ![AssyRequired](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/assyrequired/32/7621_2.png) [@AssyRequired](https://community.electricforum.com/u/AssyRequired)\ **Post date:** [February 9, 2025, 3:01am UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/6 "2025-02-09T03:01:19Z")
> [@Dday](#): > > Never thought a washer between the two could cause that. Thanks again for the suggestion. Crazy things begin to happen when you start running things that require mega currents. > JrJava - > step 3. You should oblige it. Again - Crazy things can happen. ---
**Author:** ![tonni6030](https://avatars.discourse-cdn.com/v4/letter/t/b19c9b/32.png) [@tonni6030](https://community.electricforum.com/u/tonni6030)\ **Post date:** [September 8, 2025, 1:09pm UTC](https://community.electricforum.com/t/2002-gem-electrical-issues/28852/7 "2025-09-08T13:09:04Z")
> [@Dday](#): > > Maybe someone can help me. > My neighbors just bought a 2002 gem with lithium batteries. Upon further review it has a blue motor 7.5 horsepowe and Has a battery evo lithium setup. At first the cart ran well. Easily drove at 40 mph. After driving a couple miles it smelt like burning. The positive cable between the distribution block and dc to dc converter got really hot. It melted part of the distribution block mounted to the front of cart. > Why would get so hot? Does the cart need to be reprogrammed? Any help would be appreciated. Thanks in advance. The cable may be heating up because of high current draw or a poor connection. A loose or corroded connection can create resistance, which builds heat and can melt parts like you described. Another possibility is that the wiring or components, including the [battery switch marine](https://www.mazuzee.com/index.php?route=product/category&path=323) setup, aren’t rated for the extra load from the upgraded system. I’d start by checking all connections, making sure the cable size is correct for the system, and confirming the converter is matched properly to the lithium batteries. Reprogramming might help, but first the wiring and connection issue should be fixed to avoid more damage.