Installation Guide for MADJAX models including: 02-141, 02-141 Light Kit For Club Car Tempo, 02-141, Light Kit For Club Car Tempo, Club Car Tempo, Car Tempo, Tempo
02-141 PRO SERIES LIGHT KIT INSTALLATION INSTRUCTIONS
02-141 PRO SERIES LIGHT KIT INSTALLATION INSTRUCTIONS CLUB CAR® TEMPO® ITEMS INCLUDED Front & Rear Lights Wiring Harness Mounting Screws Zip Ties Rocker Switch TOOLS NEEDED T15 Torx Socket T30 Torx Socket T40 Torx Socket Rotary Cutting tool Sandpaper Power Drill 15/32" Drill Bit We recommend professional installation. If you choose to not have this product installed by a professional, we highly recommend that you exercise caution, care, and patience when installing this product. Head Lights Column Cover Turn Signal Horn Indicator Assembly HARNESS GUIDE Driver Tail Light Passenger Tail Light Battery Hookups Tail Lights Harness Converter Brake Switch USB Port Brake Pad Horn Turn Signal Indicator Plug Driver Head Light Light Switch Passenger Head Light STEP 1: Switch key to OFF position. Place TOW/RUN switch to TOW. It is not required to remove the batteries but you do need to disconnect the main negative. STEP 2: Remove all screws securing floor mat to the vehicle. Retain hardware. Remove floor mat. STEP 3: T30 Torx Socket Remove and retain the front body screws shown. Remove the Pedal Assembly access panel. Access Panel STEP 4: Use the two indentations on each side of the receptacle cover shown to free from charge port and retain. STEP 5: Remove the screws securing the lower kick panel trim to the body. Temporarily remove trim and retain all. STEP 6: From the battery compartment, feed the front of the harness to the dash as shown. Lay harness loom in the Middle floor channel noted in picture. Route the Brake Light connectors through the center floor channel that leads to the brake compartment. STEP 7: T15 & T30 Torx Socket Remove and retain the instrument panel screws shown. Middle Floor Channel Brake Compartment HAZARD SWITCH INSTALL STEP 8: Choose one of the factory marked indentations on either the left or right of the key switch as shown. Or find a desired location on your IP to mount the hazard switch. Ensure the location is free of obstacles and will not affect dash reattachment. Using a 15/32" bit, drill a mounting hole and insert switch into dash. Secure with the ring nut from back of switch. Reattach Wires: Black wire behind LED, Blue wire on center post, and Yellow wire on top post. (See Step 16 for futher clarification) STEP 9: Plug 12-Pin connector of the turn signal module to the light kit harness. STEP 10: Route the two head light connectors and purple/black horn wires through the opening behind instrument panel to the front. Note: Red connector is for the Passenger Side Head Light. USB CHARGER INSTALL STEP 11: Using a 1 1/8" paddle bit, find a desired location on the dashboard to mount your USB charger. Ensure the location is free of obstacles and will not affect dash reattachment. Using a 1 1/8" paddle bit, find a desired location on the dashboard to mount your USB charger. Ensure the location is free of obstacles and will not affect dash reattachment. Note: If you do not have access to a 1 1/8"paddle bit, you can use the inside of the retaining nut as a template. STEP 12: Using the supplied ring nut, mount the charger to your cart. Plug the red and black 12-volt accessory connection from the light kit harness to the spade terminals on the back of the charger, red to (+) and black to (-). Note: Secondary connector can be used to supply power to another 12 volt accessory with less than 7.5 amp draw. STEP 13: Mount turn signal indicator assembly using clamps provided and tighten. Run turn signal indicator harness along steering column and insert harness through dash. STEP 14: Attach turn signal back cover to turn signal assembly. Attach column cover to steering column, secure harness in column cover void. Plug in the 12-pin connector. STEP 15: Attach horn to purple and black female spade connectors from front of harness and secure horn to metal framework under front cowl with a self tapping screw. Note: Horn is operated at the turn signal assembly. *Wires have no orientation and will work on either post. AUXILIARY SWITCH FEATURE STEP 16: The turn signal handle has a secondary, 2-position rotary switch for auxiliary 12 volt lighting such as fog lights and/ or LED light bars. There is one common negative wire and two positive wire connections to run two positive wire connections to run two different auxiliary lights. Additional wiring and lighting not included. Reinstall dashboard using retained hardware from Step 7. The blue, yellow, and black wires will be connected to the hazard switch in Step 8. AUXILIARY ROTARY SWITCH HEAD LIGHT INSTALL STEP 17: Scissors, Marker, Rotary Cutting Tool Cut out center of the supplied template. Align template to cowl using the reference points on template and trace light cut out with marker. Cut out head light hole using the inside of the marked line as a guide. Some trimming may be necessary to fit light. Use sandpaper to smooth any rough edges. Clips STEP 18: After checking if the head light fits properly, connect the head lights to the harness. Insert the bottom of the head light into the hole first, then push the top side in making sure mounting clips fuly engage the bask side of the cowl. Note: *Red 3-pin connector goes to the passenger side light. TAIL LIGHT INSTALL STEP 19: Tape Measure, Marker, 1-1/8" Hole Saw Mark the center of the taillight hole using the drawing below, then using a 1-1/8 inch hole saw, drill a hole in the location as shown in drawing. Sand hole to remove sharp edges. STEP 20: Route tail light wires through upper rear corners of battery compartment ensuring that tail light connector with red connector goes to the passenger side. Using a wire snake, pull the tail light connector through the hole in the rear body. TAIL LIGHT INSTALL STEP 21: #2 Phillips Head Connect the tail lights to the vehicle tail light wiring harness. Remove the double sided tape from the back of the tail light and mount to the rear body using screws provided. *Repeat process on opposite side. STEP 22: A A) Loosen the jam nut on brake rod. Place the forked bracket around the brake rod behind the jam nut and tighten it, sandwiching the bracket. Place the brake switch on the floor of the car with the spring running towards the back of the car to the brake switch. FRONT OF CART JAM NUT B) Adjust the brake switch so that the spring has no slack B but the switch is not engaged. Screw the brake switch to the floor of the car with self-tapping screws. C) Plug the 2 bullet connectors from the brake switch C into the corresponding bullet connectors on the light kit harness. Secure all wiring so that it is away from moving parts. STEP 23: T15 & T30 Torx Socket Safely tuck remaining harness & 12-pin connector into dash area and reattach the instrument panel. You can also reattach lower kick panel, pedal cover, charge port bezel, and floor mats using retained hardware. BATTERY CONNECTIONS STEP 24: Ensure the cart is still in TOW mode (see yellow circle below). Locate the black wire (red arrow) coming from the On Board Computer (OBC) with the yellow female bullet connector behind Battery #4. Plug the black wire with male bullet connector from the light kit harness into the OBC wire. Remove the nut from the Negative post of Battery #4 (green arrow) but do NOT remove the battery cable. Attach the red wire with ring terminal from the light kit harness to this Negative post and retighten nut. Do NOT hook the red wire to any post other than the Negative of Battery #4. Your light kit is now hooked to 16 volts, if you choose to use a Reliance voltage reducer or power converter follow the instructions included with that kit for installation. #1 #6 #3 #4 #2 #5 FRONT OF CART STEP 25: The voltage converter included must be used on all carts, electric and gas. Connect the red wire with the fuse to the main positive terminal of the battery pack. Connect the black wire to the main negative terminal of the battery pack and tighten hardware. Mount the converter to a flat surface under the seat. (Metal area is preferred). Plug the connector with the yellow and black wire into the light kit harness (you will notice a small arc when connecting). Reconnect battery and place run/tow switch to run. *Use converter on gas carts to prevent starter generator voltage spikes that could cause damage to accessories. MAIN POSITIVE (+) PLUGS INTO LIGHT KIT HARNESS MAIN NEGATIVE (-) STEP 26: Now that the power is connected, check brake switch operation. Make adjustments if needed by repeating Step 22. Replace access panel, floormat, running boards, and charger port panel using retained hardware. Return RUN/TOW switch to RUN position. Replace seat bottom. INSTALLATION COMPLETEAdobe PDF Library 17.0 Adobe InDesign 20.1 (Macintosh)