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Running lights kit installation instructions on Club Car DS model cars years
1993 to 2008. This is a well designed kit with plug together connections.
Guide teaches complete installation on a gas Club Car golf car.
This guide 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.
Suggested reading for electric Club Car golf cars.
Parts list included in kit:
Remove head lights, tail lights, harness and various parts from bags. Harness has two portions the main harness and the tail lights' sub-harness. We have a guide for this harness: Click on this link to learn about the L21 harness.
Read through entire guide to become familiar with harness components. Remember the harness is a universal harness to six different light kits so there may be minor differences between this guide and the harness wiring guide. If the tail lights sub harness is not connected do so at this time. Read through this entire guide before beginning installation.
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 inch 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. Tail lights position is car owner's choice. Tail lights can be oriented vertical or horizontal.
This guide 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.
Suggested reading for electric Club Car golf cars.
Parts list included in kit:
1 - main wiring harness
1 - tail lights sub-harness
1 - toggle switch installed in harness
1 - 12V 30AMP Relay
1 - fuse installed in holders
7 - cable ties
2 - tail light assemblies
1 - head light assembly drivers side
1 - head light assembly passenger side
1 - tail light cut out template
1 - head light cut out template
1 - tail lights sub-harness
1 - toggle switch installed in harness
1 - 12V 30AMP Relay
1 - fuse installed in holders
7 - cable ties
2 - tail light assemblies
1 - head light assembly drivers side
1 - head light assembly passenger side
1 - tail light cut out template
1 - head light cut out template
Tools & supplies required:
Scissors
Cordless driver or variable speed drill
Reciprocating saw
Fine tooth blade for saw
5/16 inch drill bit
15/32 inch drill bit alternate substitute 1/2 inch drill bit
Black magic marker
Electrical tape
Cordless driver or variable speed drill
Reciprocating saw
Fine tooth blade for saw
5/16 inch drill bit
15/32 inch drill bit alternate substitute 1/2 inch drill bit
Black magic marker
Electrical tape
Remove head lights, tail lights, harness and various parts from bags. Harness has two portions the main harness and the tail lights' sub-harness. We have a guide for this harness: Click on this link to learn about the L21 harness.
Read through entire guide to become familiar with harness components. Remember the harness is a universal harness to six different light kits so there may be minor differences between this guide and the harness wiring guide. If the tail lights sub harness is not connected do so at this time. Read through this entire guide before beginning installation.
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 inch 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. Tail lights position is car owner's choice. Tail lights can be oriented vertical or horizontal.
Holes cut into body string harness throughout
cart. Secure with cable ties. Light assemblies attach to harness as
follows.
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 wired to come on with the clear headlights. How to make this a turn signal package goes beyond the scope of this guide. Head light shown facing away.
Harness front end is the most complex portion of the light kit. The upper left picture is one of the harness ends, there are two, one for each headlight assembly. The middle picture shows the two cream plugs, one from the headlight and one from the harness. Also shown in the middle picture is the harness red wire and the headlight's marker light black wire. Its not intuitive but the red wire and black wire plug together. Yes changing wire colors in a system is normally taboo but this is correct for this harness and light kit. Top right picture shows all wires connected as follows.
Light switch exact location is car owner's preference. Choose a place on the dash. Use a 15/32 inch drill bit for switch location. Don't have a 15/32 inch drill bit? Substitute 15/32 inch with a 1/2 inch 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.
Attach power supply leads. For simplicity's sake this guide shows installation on a gas golf car battery. Harness red wire has a replaceable 15 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.
Use cordless driver to secure head lights and tail lights to body. Use cable ties to secure harness to golf car. Light kit installed, lights should turn on and off without any trouble. If they do not work below is a troubleshooting guide.
Problem
Lights had a quick bright flash and are now dark, and / or plastic bezels are melted.
Solution
Incorrect power supply, lights are hooked up incorrectly to batteries. Too much power the lights will flash bright and then go dark because the bulbs are burnt out. Top of this guide has links to proper installation for electric golf cars.
Problem
Sparks when attaching ground wire.
Solution
Do not attach ground wire to frame, attach ground wire to battery.
Problem
Lights do not turn on.
Solution
Bad relay, its rare but a relay is defective right out of the box. Replace with new relay, bad relay is a covered warranty item.
Problem
Lights do not turn on
Solution
Bad on / off switch, its rare but a push pull switch can be defective right out of the box. Replace with new switch, bad switch is a covered warranty item.
Tail lights
connections:
White is hot, black is ground, red is not
used.
Tail light snap connector to tail light snap connector.
Coil off and tape red wire to tail light.
Tail light snap connector to tail light snap connector.
Coil off and tape red wire to tail light.
Head lights
connections
Harness cream plug to headlight cream plug black
wire ground, red wire hot.
Harness black wire ground with loop connection to marker light terminal stud.
Harness red wire hot male connection to marker light black female connection.
Harness black wire ground with loop connection to marker light terminal stud.
Harness red wire hot male connection to marker light black female connection.
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 wired to come on with the clear headlights. How to make this a turn signal package goes beyond the scope of this guide. Head light shown facing away.
Harness front end is the most complex portion of the light kit. The upper left picture is one of the harness ends, there are two, one for each headlight assembly. The middle picture shows the two cream plugs, one from the headlight and one from the harness. Also shown in the middle picture is the harness red wire and the headlight's marker light black wire. Its not intuitive but the red wire and black wire plug together. Yes changing wire colors in a system is normally taboo but this is correct for this harness and light kit. Top right picture shows all wires connected as follows.
Light switch exact location is car owner's preference. Choose a place on the dash. Use a 15/32 inch drill bit for switch location. Don't have a 15/32 inch drill bit? Substitute 15/32 inch with a 1/2 inch 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.
Attach power supply leads. For simplicity's sake this guide shows installation on a gas golf car battery. Harness red wire has a replaceable 15 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.
Power supply
connections:
Red is hot, black is ground.
Harness red hot wire loop terminal attaches to positive power supply battery or voltage reducer terminal.
Harness Black ground wire loop terminal attaches to negative power supply battery or voltage reducer terminal.
Harness red hot wire loop terminal attaches to positive power supply battery or voltage reducer terminal.
Harness Black ground wire loop terminal attaches to negative power supply battery or voltage reducer terminal.
Use cordless driver to secure head lights and tail lights to body. Use cable ties to secure harness to golf car. Light kit installed, lights should turn on and off without any trouble. If they do not work below is a troubleshooting guide.
Problem
Lights had a quick bright flash and are now dark, and / or plastic bezels are melted.
Solution
Incorrect power supply, lights are hooked up incorrectly to batteries. Too much power the lights will flash bright and then go dark because the bulbs are burnt out. Top of this guide has links to proper installation for electric golf cars.
Problem
Sparks when attaching ground wire.
Solution
Do not attach ground wire to frame, attach ground wire to battery.
Problem
Lights do not turn on.
Solution
Bad relay, its rare but a relay is defective right out of the box. Replace with new relay, bad relay is a covered warranty item.
Problem
Lights do not turn on
Solution
Bad on / off switch, its rare but a push pull switch can be defective right out of the box. Replace with new switch, bad switch is a covered warranty item.
Guide created: 03/31/08 (updated 10/01/08)
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