How to Install Lights on Your EZGO Golf Cart
Posted by Joe Mutton on
A good video on how to install Part# 627421 Gas Economy Light Kit.
Remove cup-holder and front panel; this facilitates removal of front 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
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
Once harness is in engine bay, route harness under air intake and connect to battery; clip fuses to crossbracket on the battery tie down
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.
Front of wiring harness looks this way:
Route the switch connector to the instrument panel
Use templates included with lights kit to make mounting holes and cutout section for rear lights.
Place the four metal clips over the new holes and then place taillight; fasten into place
Finally, plug in each taillight
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
Connect the headlight to the wiring harness via the two plugs; one for man beam, the other for turn indicator
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.
Connect red wire from harness to battery terminal; connect ground wire from chassis to battery
Now, you are ready to drive with lights.
Think you missed a spot? Watch the complete video