How to Install Lights on Your EZGO Golf Cart

Posted by Joe Mutton on Mar 12, 2021

A good video on how to install Part# 627421 Gas Economy Light Kit.

LED Factory Light Kit

Halogen EZGO Factory Light Kit

Remove Rocker Panels and Rubber floor cover, exposing the pedal cover--cover near gas & brake pedals

Remove cup-holder and front panel; this facilitates removal of front cowl and instrument panel.

Remove this panel to remove cowl and instrument panel

Now for front cowl and instrument panel

Disconnect wires from instrument panel and set aside.

Next, we must make room for wiring harness and remove eight bolts that secure the cart body to the chassis

Remove the metal wiring channel cover at the front of the body

EZGO Remove Wiring Bracket Front of Body

We can now install the wiring harness by routing the fuse end from the cup-holder through the wire-harness channel in the chassis to the engine compartment

Wire Harness From Dash to Engine Compartment

Once harness is in engine bay, route harness under air intake and connect to battery; clip fuses to crossbracket on the battery tie down

Fuses on harness secured to battery crossbracket

Connect harness ground wire to chassis

Ensure rear part of wiring-harness goes over the fender-liner; insert push-clips into holes in metal support.

Rear part of wiring harness goes over fenderliner and pushclips are in metal support beam holes

Front of wiring harness looks this way:

Route the switch connector to the instrument panel

INSTALL TAILLIGHTS

Use templates included with lights kit to make mounting holes and cutout section for rear lights.

EZGO template for rear lights

Place the four metal clips over the new holes and then place taillight; fasten into place

Finally, plug in each taillight

INSTALL HEADLIGHTS

Same as taillights; use templates to cut sections out for headlights

Next, take dashboard, remove ignition switch and use template to cut mount for lights switch

after cutting, install switch

Now, begin reinstalling components; this is done in reverse order of disassembly, with notes and images regarding the lights addition.

Connect light-switch in dash

Replace front cowl

INSTALL HEADLIGHTS

Connect the headlight to the wiring harness via the two plugs; one for man beam, the other for turn indicator

Install headlight

The composite light assembly has pushtabs; the unit will snap into place with a slight push

Now, replace remaining components; what should be remaining are: ziptie any loose wires, tighten body to chassis, replace pedal cover, rubber flooring, rocker covers and cup holder.