Installing Lights on a Golf Cart

By Chad Buleen

Owning a golf cart can be advantageous, particularly if you want to customize it. Installing lights on golf carts can be especially helpful during early-morning rounds or rounds that end just before dusk.

Instructions

Difficulty: Moderately Challenging
Step 1
To cut the holes: Measure the size of the lights by tracing them on a piece of paper. Tape the paper on the front of the golf cart and use a jigsaw to cut out this section, where the left headlight and the right headlight will be placed. Cut just inside of the line on the paper. Before using the jigsaw, take a step back and make sure the papers are aligned.
Step 2
Insert the headlights into the holes created by the jigsaw. If they are loose, use putty to hold them in place for the time being.
Step 3
Use the bezel as a template to drill a 1/32-in. hole on the upper part of the inside corner. Insert a 1/8 in. x 3/4 in. screw into the hole through the cowl, but do not tighten. Do the same on the lower outside corner and the two remaining corners. Repeat these steps on the passenger side.
Step 4
Repeat steps 1-3 for the taillights.
Step 5
To install the wire harness: Jack up the front of the cart and set it on jack stands to hold it in place. Be sure that the safety break is on. Block the rear wheels with stones or bricks to keep them in place.
Step 6
Reach onto the wiring harness and pull to remove the "push/pull" switch. Position the wiring harness so that the two taillights are toward the back part of the cart. Thread the harness to the front of the cart so that the headlight connectors and ignition switch connectors are in the front and underneath the central part of the cowl.
Step 7
Take the wires that are connected to the "push/pull" switch and thread them along the steering column. Take off the knob, washer and retaining nut from the switch and reconnect it underneath the harness. Reach your arm under the driver's side and place the shaft of the switch into the panel hole and use a washer and a nut to secure it into place. Replace the knob.
Step 8
Use zip ties to secure the steering column so that it does not wiggle and stays in place. The remaining wire looms should run back to the back of the cart along the cart's frame. The shorter loom should be connected to the taillight behind the driver. Connect the other loom to the back of the passenger side. Place the positive loom wire on the positive terminal on the battery and pull the "push/pull" switch so that it is now in the "On" position.
Step 9
Test the connection by touching the negative wire to the negative battery terminal for a moment. Visible sparks are fine, however a flash that arcs and is brighter than the sparks may mean there is a short in the system. As long as there are no arcing flashes, push on the "push/pull" switch until it is turned off.

Look to make sure that none of the harness is below the frame and that there are no pinched or rubbing wires. Tie up the harness with zip ties to ensure they stay in place.

Lower the car from the jack and you are ready to use the lights on the golf cart.

Tips & Warnings

If the wires or push/pull switch touches any part of the frame, an electrical short could occur.

About The Author

Chad Buleen is a Society of Professional Journalists-award winning newspaper and magazine writer and editor with more than 10 years' experience. He has been published in "Utah Spirit," "Charleston Gazette," "Idaho Falls Post Register" and numerous other publications. Buleen holds a Bachelor of Arts in communications with an emphasis in print journalism from Brigham Young University-Idaho.

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