This guide explains running lights kit installation.  Club Car chrome lights kit fits years 1984 to 2002 and 2003 to 2008 DS model cars. 

       

This is a well designed kit which includes a wiring diagram.  This guide goes beyond the basic wiring diagram and teaches complete installation on a gas Club Car golf car.  Installation is principally the same for 36V and 48V electric cars with the sole exception of the power supply.  I have other guides that are specific to 12V power from electric golf cars and electric Club Car golf cars.  If you have a 36V golf car or 48V golf car these guides should be read before attempting to install this light kit.



Remove head lights, tail lights, harness and various parts from bags.  Harness has two portions the main harness and the horn's sub-harness.  Read through entire guide to become familiar with harness and kit components.  Remember the harness is a universal harness so there may be differences between this guide and the harness wiring diagram.  Follow this guide for club car chrome lights kit.  Color coding of light assembly wires and harness wires match all around.  Plug 4 pin relay into main harness white 4 pin receptacle. 
With a sound understanding of the kit proceed to cutting the body for light install. Use a scissors to cut out the hole location templates.  Details are printed on the templates.  Position template on car body and mark the cut out lines.  Use drill with 5/16" bit to drill holes where the saw blade needs to turn.  Basically on the corners of the holes to the inside of the marked cut out area.  Holes drilled use reciprocating saw to cut out the body.   
Horn installation requires a 5/8" hole drilled through the floorboard on the drivers side of the car.  Insert horn button and secure.  Exact position is car owner's preference, generally its located somewhere on the sloped area between the level floor and the car console.  Horn attaches to the frame on the underside of the front cowl.  Position horn on the aluminum frame and drill two 5/16" holes 1-1/8" apart.  Use 5/16" x 1" bolt washer and wizz nut to secure horn to frame.


Attach tail lights to harness.  Tail lights have three wires, red, brown and black.  Red wire is not used in a running lights setup.  Red wire is for turn signals and brake lights.  Since red wire is not used coil and tape off.  Secure red wire to tail light with electrical tape.  Tail light shown from face down.


Attach head lights to harness.  Head lights have separate wires for white lights and amber markers.  Since this is a running lights only kit amber marker light is not used.  Unplug pigtail from amber light.  Use black electrical tape to cover marker light terminals.  Save pigtail for future use to convert this kit into a turn signal package.  How to make this a turn signal package goes beyond the scope of this guide.  Head light shown face down.


Light switch exact location is car owner's peference.  Choose a place on the dash.  Use a 15/32" drill bit for switch location.  Don't have a 15/32" drill bit?  Subsititue 15/32" with a 1/2" drill bit.  Hole will be a little bit large but will pass.  Remove knob, its threaded righty tighty lefty loosey.  Remove knurled lock nut.  Put into hole, secure with nut and washer to inside of dash, knurled nut and know to outside of dash.  Light switch controls the ground side of the relay for on and off operation of the system.


Attach power supply leads.  For simplicity's sake this guide shows installation on a gas golf car battery.  Both harness red wire and harness yellow wire have replaceable 20 AMP spade fuse in watertight fuse holder. Its mandatory to ground the harness to the battery.  Never frame ground a golf car light kit.  If you don't know what frame ground is thats fine.  Just attach the black wire to the negative battery terminal. How to attach a wiring harness to an electric golf car goes beyond the scope of this guide.  Do not attach to all batteries on an electric golf car.