When I recently mentioned that I wanted a 4-wheeler, my wife said I needed to get something that our girls could drive around and suggested an all-terrain utility vehicle like the Yamaha Rhino.  These are basically a small Jeep and they are something you drive and not ride.  I also didn't think it was something our girls could safely drive themselves for quite some time.  So, my wife suggested that I get a four wheeler and golf cart.  I couldn't argue with that.  So, we bought a 2001 EZ Go TXT golf cart the girls could drive around the neighborhood and we could use to haul stuff to the beach at Mimi's and Tata's lake house.  It didn't take me long to realize that a golf cart was a lot like a Jeep;  you can go on endlessly customizing it.  So, the first thing I bought was a headlight/tail light kit.  The installation was fairly easy once I figured out the instructions.  Read on to see how to do it.

 

The first thing you need to do is get buy the headlight/tail light kit.  I bought mine at Cart Stuff Depot.  The kit came complete with the lights, all wiring, templates for cutting the necessary holes, and a switch.  For comparison purposes, I have provided a picture of the golf cart before the lights were added (picture 1).

 

The whole process is fairly simple.  I started with the front lights by cutting out the templates and securing them to the golf cart with some quick grips and duct tape.  Then I traced the line I needed to cut with a thin red sharpy which would be easy to see on the white golf cart (picture 2).

 

I removed the templates, leaving only the red line, and used a jig saw to cut a whole in the front of the cowling (picture 3).  Look carefully, and you will notice that I used a quick grip to secure the interior dust shield away from the cowling so that I wouldn't cut it with the jig saw.

 

Then, with the assistance of my youngest, Emma, I connected the wiring to the batteries (picture 4).  The only thing to remember here is that you must connect positive to the positive of one battery and negative to the negative of a different battery.  Since these are 6-volt batteries, using 2 different batteries will give you the necessary 12 volts needed for the lights.

 

Then I secured the control module that came with the wiring kit inside the battery compartment in an out of the way location.  Now I could run the headlight wires to the front and see where everything would run.  Be sure to run the wires so that they are out of the way.  Once I was comfortable with the wires, I cut out the other front headlight hole, hooked up the wires, tucked the headlights into the holes, and secured them to the cowling with the provided, self-tapping screws.  When screwing the head light into place, be sure to position the light so that the screws will have enough cowling to bite into.  Now it was time for the switch. 

 

Most installations I have seen have the switch on the vertical panel below the seat cushion, next to the forward/reverse switch.  I preferred it on the dash, so I ran the wiring to the dash (picture 5).  You have to make a decision here.  I put the switch next to the ignition key switch.  I had to work the wiring very carefully because it really isn't long enough for this.  I also had to work pretty hard to cut a hole in the panel because it is made of metal.  So, instead of an easy wiring set up and a quick hole for the switch, I spent quite a bit of time running the wires in a way that they would reach and filing a hole in the dash.  But, in my opinion, it was worth it.

 

Since the switch wires were in the front along with the headlight wires, I waited until I was done with the switch before snugging up any excess wire and securing everything with zip ties.  At this point, I have functional headlights.  Now it's time to install the tail lights.

 

The tail lights were pretty much the same as the headlights.  Actually they were a little easier because the template was better and the wiring paths were easier to get to.  After cutting out the template, I secured it to the back of the cowling as instructed (picture 6).  Then I put the jigsaw to work again cutting out the tail light holes (picture 7).  After I ran the wires from the control module in the battery compartment to the tail lights and hooked up the tail lights, I secured the tail lights to the cowling using the provided screws. Again, be sure to position the light in the hole making sure that the screws will have enough cowling to bite into. 

 

Then I snugged up all excess wire and secured it all with zip ties.  The wiring kit comes with more than enough wire which ends up as extra in the battery compartment.  So, I neatly coiled that up and secured the small bundle of wire in an out of the way spot in the battery compartment (picture 8)

 

My oldest, Abby, took her sister, Emma, and I for a short night ride that night to see how they worked.  We were all delighted (picture 9).

 

That wraps up this Outdoor-Joe Project.  I hope it helps with your headlight/tail light installation.  I don't have the 4-wheeler yet but hope to get it soon.  So, check back not only for more golf cart projects, but for some ATV projects as well. 

If you have any questions, send me an e-mail. 

Picture 1:  Golf cart before lights were installed

 

Picture 2:  Front templates secure in place

 

Picture 3:  Hole cut out for headlight

 

Picture 4:  Connecting to the batteries

 

Picture 5:  Switch in dash

 

Picture 6:  Rear template secure in place

 

Picture 7:  Hole cut out for tail light

 

Picture 8:  Wiring secured in battery area

 

Picture 9:  Finished product