Madjax ALPHA Custom Body Installation Instructions
This guide provides step-by-step instructions for installing the Madjax ALPHA Custom Body Kit on a Club Car Precedent golf cart.
Kit Contents
The ALPHA Custom Body Kit includes:
- Front Cowl and Rear Body
- Automotive Style Flush Mount LED Headlights and Tail Lights
- Off-Road Style Front Grill
- Color Infused Injection Molded Flexible Plastic
- High Gloss Clear Coat Finish
Component Overview
The kit includes the following main components:
- Cowl
- Rear Body
- Headlights
- Tail Lights
- Light Mounting Brackets
- Front Cowl Bracket (05-057)
- Alpha Front Harness
- Frame Extenders (05-063)
- Alpha Bucket Harness
- Hardware Packs
- Grills: Off-Road Grill (05-021), Street Grill (available in Red, White, Blue, Black), Black Off-Road Grill (05-083)
- Hood Scoop (Sold Separately, available in Red, White, Blue, Black)
Installation - Front Cowl
Follow these steps to install the front cowl:
- 1
Switch the golf cart's key to the OFF position. Place the TOW/RUN switch to TOW. Disconnecting the main negative battery terminal is recommended, though removing batteries is not required.
- 2
Remove the factory canopy and struts. Retain all hardware. If applicable, remove the rear seat kit. Note: Front tires may have been removed in the original documentation for instructional clarity.
- 3
Remove four screws around the front brow area and retain them. Then, remove the front brow, followed by the front cowl.
- 4
Temporarily remove the cowl support to detach the front fascia. Once the front fascia is removed, reattach the cowl support. Remove the original equipment manufacturer (OEM) bumper or light kit at this time.
Cowl Assembly
- 5
Flip the cowl over and locate the six dimples on the underside.
- 6
Using the six small screws and washers included with the hood scoop, attach the hood scoop to the underside of the cowl. Tighten by hand with a Phillips screwdriver; do not overtighten.
- 7
Attach the grill to the front of the cowl using the supplied hardware. Both street and off-road grills attach identically. Use the 5/8" screws and flat washers from hardware pack #1. Note: Flip the cowl over and place it on a flat surface with a soft material to prevent scratching.
- 8
Attach the grill using the provided hardware. Tighten by hand with a Phillips screwdriver; do not overtighten.
- 9
The grill is now installed on the cowl.
Headlight Mounting
- 10
The eight small brackets pictured will be used to mount the front headlights.
- 11
With the cowl inverted, attach two of the 2" headlight brackets to the cowl using the large head half-inch screws. Ensure the slotted holes face inward.
- 12
Attach the smallest 1.5" (L) bracket to the top inside mounting tab. Attach a 2.25" (L) bracket to the remaining mounting tab. Ensure the slotted holes face inward.
- 13
With the cowl inverted, verify that your light tab bracket locations match the provided illustration.
- 14
Insert the headlight through the front of the cowl. Use the 1-inch screws and springs from the hardware pack to attach the headlight to the mounting tabs.
- 15
Ensure the screws and springs are installed as shown, with the springs positioned between the light housing and mounting brackets. If lights are not flush, loosen screws and adjust. Repeat this process for the other side.
- 16
Attach the shorter of the two cowl angle brackets to the middle mounting bracket using the supplied hardware and tighten.
Cowl Assembly Addendum
- 1
Insert Carriage Head Bolts into the cowl at the indicated locations.
- 2
Attach the grill to the cowl.
- 3
Install the bracket to the carriage bolts using the provided hardware.
Bracket Assembly and Cowl Attachment
- 17
Attach the longer angle bracket using the remaining hardware. This bracket will connect to the cowl in the next step.
- 18
Using the remaining hardware from pack #1, attach the mounting bracket to the cowl/grill assembly as shown.
- 19
The assembled bracket should resemble the provided illustration.
- 20
With the cowl fully assembled, it is ready to be attached to the cart. Insert the frame extensions into the frame, ensuring the channel side faces upward, and slide them into place as shown.
- 21
With assistance, place the cowl over the front underbody. The cowl mounting bracket should align with the OEM mounting points on the frame that secure the OEM bumper or light bumper.
- 22
Using hardware from pack #2, attach the cowl to the front underbody. Ensure screws are flat and do not overtighten.
- 23
Using hardware from pack #2, attach the light bar or OEM bumper to the frame extensions. If installing the Armor Bumper (part #14-018), do so now.
- 24
Using the retained hardware from step 3, reattach the brow over the new cowl.
FRONT COWL COMPLETE
Rear Body Tear Down
Follow these steps to remove the original rear body:
- 25
Remove the seat. Loosen the OEM body by removing four screws and retaining hardware.
- 26
Remove the forward and reverse switch bezel, retaining the hardware and bezel.
- 27
Take a photograph of your switch's wiring for reinstallation reference.
- 28
Once the body is free, remove the rear body.
- 29
Remove and retain the side rocker panels, then the floor mat.
- 30
A) Remove and retain the charge port trim bezel as shown. B) Remove the trim panel as shown, retaining all hardware.
- 31
Remove and retain the dash access panel.
Alpha Harness Installation
Install the Alpha wiring harness:
- 32
Feed the Alpha bucket harness 12-pin plug through the battery box channel. Note: Alpha tail lights use 4-pin connectors; this kit is not compatible with basic or pre-installed bucket harnesses, or with aftermarket, factory gas carts, and factory 2008.5 and older carts.
- 33
Remove and retain the pedal assembly cover. Feed the brake harness leg into the pedal assembly as shown. If installing a light brake kit, do so now. Note: The blue and green wires on the Alpha harness must be connected together for brake light operation.
- 34
Run the Alpha bucket harness through the channel in the floorboard and feed it to the dash.
Power Connections
Connect the power supply for the lighting system.
For Gas Vehicles
Attach the blue wire with the fuse holder to the positive battery post. Attach the black wire to the negative battery post.
12 Volt Battery Installation (for vehicles without DC to DC converter):
- Remove the seat bottom and the electronic component cover between the batteries.
- Locate the blue wire from the #4 battery positive connection and connect it to the long lead of the fuse assembly.
- Locate the single 12-gauge blue wire with a spade terminal from the passenger side of the electronic component area and connect it to the short lead of the fuse assembly.
- Secure all loose wires.
- Replace the electronic component cover and test the lights.
For Vehicles with 8 Volt Batteries (Requires DC to DC Converter)
It is recommended to use Madjax part numbers MJ1230C, MJ1220C, or MJ1612VR. Follow the instructions supplied with your converter. Use a multimeter to check the voltage for 12V+ before turning on the light kit to ensure the converter is functioning correctly.
16 Volt Connection for 8 Volt Batteries with Voltage Reducer (e.g., MJ1612VR):
- The ground or negative wire is a black wire with a female barrel terminal, located at the rear of the battery box behind battery #3.
- The 16-volt positive connection (refer to Picture 4) is a short blue wire with a spade terminal, located on Battery #3's negative terminal as illustrated. This connection is used with a 16-volt to 12-volt DC to DC converter.
48 Volt Connection for Voltage Converter
The 48-volt positive connection is a short blue wire with a spade terminal, located on battery #6 (as shown in Picture 4). ONLY USE THIS CONNECTION IN CONJUNCTION WITH A 48 VOLT TO 12 VOLT REDUCER/CONVERTER, OR BULB FAILURE WILL RESULT.
Once your converter is hooked up, the blue wire on the bucket harness connects to the 12-volt output, and the black wire connects to the 12-volt negative.
Note for ERIC cars without OBC:
- If using the 16-12v Reducer MJ1612VR, the 16-volt positive connection is the positive post of battery 5, and the 16-volt negative connection is the negative post of battery 6.
- If using the 48-12v Converter, the 48-volt battery connection is the positive post of battery 1, and the negative connection is the negative post of battery 6.
Harness Routing and Connections
Complete the wiring connections:
- 35
Take the 4-pin tail light connector (with the yellow wire) and route it through the passenger side rear access opening of the battery box. Repeat this process on the driver side.
- 36
Attach the Alpha bucket harness 12-pin connector to the front light harness 12-pin connector as shown.
- 37
Run the Alpha light harness through the channel in the dash to the front cowl.
- 38
If installing an upgrade turn signal switch, do so now and reattach the panel.
- 39
Attach the headlight to the front harness. For the Daytime running light feature, unplug the red/white wire from the blue wire on both headlights and connect the red/white wires to the switched 12-volt output of the voltage converter.
Rear Body Installation
Reinstall the rear body components:
- 40
Place the rear body onto the cart. Reinstall the floor mat, F-N-R switch, charge port trim, and side rocker panels.
- 41
Starting from the front of the battery box, work the rear body into the channel of the underbody and trim. Once the front is in place, reattach the two forward screws as shown.
- 42
Move to one side of the rear body and work that section into the channel. Once the body is in position, reattach the retained screw at the battery box. After completing one side, repeat the process on the other side.
- 43
Take the passenger tail light (with the red 4-pin connector) and attach it to the passenger side tail light bracket labeled (P).
- 44
Plug the tail light harness into the bucket harness.
- 45
Locate the pre-drilled hole shown in your underbody.
- 46
Using the 8mm x 45mm hardware, attach the light mounting bracket to the underbody from the tire well as shown. Once the bolt is started, tighten it. This method allows for quick removal of the tail lights. Repeat this process on the other side.
- 47
Reattach all factory seats, top, struts, etc.
INSTALLATION COMPLETE
Club Car®, Precedent®, and DS® are registered trademarks of Ingersoll Rand, Inc. Reference to Ingersoll Rand's trademarks and products is solely for the purpose of identifying golf carts with which this Madjax product is compatible. Madjax products are aftermarket parts and are not original equipment parts. Madjax is not connected, affiliated with, or sponsored by Ingersoll Rand® or Club Car®.
