STEP 1: HEADLIGHT HOLE CUT-OUTS

A) Place the HEADLIGHT LOCATING TEMPLATE on the PASSENGER side front cowl, facing OUT and UP. Carefully position the template so that the UPPER CENTER alignment line follows the mold line on the center portion of the cowl and the LOWER alignment line follows the lower mold line of the cowl. Temporarily tape the template into position and then mark the cut-out area with a black felt-tip pen or other suitable marker.

B) Remove the template from the PASSENGER side, flip it over and position it on the DRIVER side. Repeat the procedures you completed in STEP 1-A.

C) Apply 2" wide masking tape along the outer edges of the cut-out lines on the PASSENGER and DRIVER side. (This will provide protection for the cowl surface and allow you to follow the marked lines more easily while cutting.) NOTE: Use caution when applying tape to freshly painted surfaces.

D) Beginning on the DRIVER side, carefully drill a hole in each corner of the cut-out area. The size of the drill bit to use should

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be large enough to allow insertion of the blade of a power STEP 3: POWER CONNECTION AND FINAL STEPSjigsaw. DO NOT DRILL OUTSIDE OF THE CUT-OUT LINE. E) Repeat STEP 1-D on the PASSENGER side.

F) Again beginning on the DRIVER side and using a power jig saw, insert the cutting blade into one of the holes previously drilled in STEPS 1-D & E and carefully cut along the marked line to remove the piece of cowl. Smooth all cut edges with a file or 80grit sandpaper.

G) Repeat STEP 1-F on the PASSENGER side. H) Center-punch each outer corner of the DRIVER and

NOTE: THIS LIGHT KIT IS DESIGNED TO BE USED WITH 12V-DC POWER ONLY! ON GAS CARS YOU CAN CONNECT TO THE POSITIVE AND NEGATIVE TERMINALS OF THE 12-VOLT BATTERY. ON 36-VOLT ELECTRIC CARS YOU CAN USE TWO OF THE SERIES-CONNECTED 6VOLT BATTERIES (THE POSITIVE WIRE OF THE LOOM GOES TO THE POSITIVE TERMINAL OF ONE OF THE BATTERIES AND THE NEGATIVE WIRE OF THE LOOM GOES TO THE NEGATIVE TERMINAL OF THE OTHER BATTERY.) REFER TO WIRING INSTRUCTIONS. ON 48-VOLT

PASSENGER HEADLIGHT BEZELS, approximately 3/16" from ^{SYSTEMS, YOU MUST USE A VOLTAGE REDUCER.} the horizontal and vertical edges. Using a 1/8" drill bit, drill each _{Please refer to the proper OEM wiring diagram, along with the wiring} ^{corner in both bezels and set aside until STEP 3, HEADLIGHT} diagram included in this kit, for clarification of the following wiring BEZEL ASSEMBLY INSTALLATION. _procedures:

A) Connect the POSITIVE wire of the loom to the POSITIVE

STEP 2: TAILLIGHT HOLE CUT-OUTS

terminal of the battery or power supply. Before you connect the

A) Position the TAILLIGHT LOCATING TEMPLATE on the driver side rear cowl, facing UP. Carefully position the template so that the inside alignment line is on the inside edge adjacent to the bag well. Temporarily tape the template into position and then mark the rectangular cut-out area with a black felt tip marker.

NEGATIVE wire of the loom to the NEGATIVE terminal of the battery or power supply, pull the knob of the headlight "ON-OFF" switch to the "ON" position. Now, briefly touch the NEGATIVE wire of the loom to the NEGATIVE terminal of the battery or power supply. (NOTE: It is normal to have minor "sparks" when

_{B) Remove the template from the driver side and move it to the} you complete this procedure.) All of the lights should illuminate. _{passenger side. Repeat the procedures you completed in STEP} B) Push the knob of the headlight "ON-OFF" switch to the "OFF" _2-A. position and then connect the NEGATIVE wire of the loom to the

C) Similar to the way you did in STEP 1-D, and beginning on the ^{NEGATIVE terminal of the battery or power supply.}

_{DRIVER side, carefully drill a hole in each corner of the cut-out} C) Inspect your entire wiring and loom installation, insuring that _{area. The size of the drill bit to use should be large enough to} nothing is pinched or rubbing and that no portion of the harness

allow insertion of the blade of a power jigsaw. DO NOT DRILL ^{is below the frame. Secure the wires and loom as needed with}

_{OUTSIDE OF THE CUT-OUT LINE.} the plastic wire ties provided. _{D) Repeat STEP 2-D on the PASSENGER side.} D) Remove the safety jack stands. The headlights are now ready to

E) Apply 2" wide masking tape along the outer edges of the cut-out ^{be adjusted. (See STEP 4, Page 8.)} lines on the driver and passenger side. (This will provide protection for the cowl surface and allow you to follow the marked lines more easily while cutting.)

NOTE: Use caution when applying tape to freshly painted surfaces.

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frame, thread the harness with front headlight connectors and ignition switch connectors towards the front of the vehicle and under the approximate center area of the front cowl.

B) Connect the female "snap connectors" to the male "snap connectors" on the headlights.

C) Remove the upper "snap-in" portion of the beverage holder so that you can access the area behind the dash. Thread the two wires for the PUSH / PULL switch along side of the steering

F) Again beginning on the DRIVER side and using a power jig saw, insert the cutting blade into one of the holes previously drilled in STEPS 2-D & E and carefully cut along the marked line to remove the piece of cowl. Smooth all cut edges with a file or 80grit sandpaper.

G) Repeat STEP 2-G on the PASSENGER side.

STEP 3: HEADLIGHT BEZEL ASSEMBLY INSTALLATION

column and temporarily bring them up through the first hole for the beverage holder. Retrieve the PUSH / PULL switch that you _{A) Insert the DRIVER and PASSENGER headlight bezel}

removed at the beginning of STEP 2. Remove the knob, retaining nut and washer. Connect the two harness wires on the switch and tighten securely.

D) Put the PUSH / PULL switch back down in the hole for the beverage cup and then insert the threaded plastic shaft into the hole you drilled in STEP 1-D. Install the washer and nut on the shaft and tighten securely. Install the knob onto the shaft and tighten securely.

E) Insure that the switch wires are free from obstructions and sharp edges and secure to the steering column with a plastic cable tie. F) Position the upper "snap-in" portion of the beverage holder over the lower and snap into place. G) Return to the battery/engine compartment on the PASSENGER side of the vehicle.

assemblies in their respective hole cut-outs in the front cowl and check for overall fit. (You may have to file or sand the cut-out areas slightly to insure adequate clearance.) Align both bezel assemblies in the hole cut-outs and temporarily tape into place. Step back a few feet from the cowl and insure that the overall horizontal and vertical alignment matches on both sides. (You may want to take some reference measurements from the center and bottom of the cowl edge to confirm alignment.)

B) Once you are satisfied with the bezel alignment you are ready to fasten the assemblies to the cowl. Starting on the DRIVER side and using the bezel as a template, drill a 1/32" hole in the cowl at the upper inside corner. Insert a black 1/8" x 3/4" sheet metal screw about 3 threads into the hole. DO NOT TIGHTEN AT THIS TIME. Still using the bezel as a template, move to the

H) Run the remaining wire looms of the harness towards the rear of the car, following along the tubular frame. The short loom connects to the DRIVER side taillight and the long loom follows lower outside corner, drill a 1/32" hole into the cowl and then insert another black 1/8" x 3/4" sheet metal screw about 3 threads into the hole. DO NOT TIGHTEN AT THIS TIME. You

_{the rear frame cross tube and connects to the PASSENGER} can now drill the remaining two holes, inserting a black 1/8" x _{side taillight.} 3/4" sheet metal screw as you did previously. DO NOT TIGHTEN AT THIS TIME.

I). Connect the respective female "snap" connectors to the male _{C) Repeat STEP 3-B for the PASSENGER side.}snap connectors of the each taillight assembly. D) You are now ready to permanently fasten the headlight bezel assemblies to the front cowl. DO NOT OVER-TIGHTEN THE *On 1995 and early 1996 G14 gas, the battery is located on the _{SCREWS, ESPECIALLY IN THE FLEXIBLE PLASTIC COWLS. Starting}

PASSENGER SIDE.

YOU ARE NOW READY TO CONNECT THE WIRE LOOM TO THE POWER SUPPLY.

with the DRIVER side bezel at one of the upper corners, push in on the bezel so that it is tightly against the cowl and hand-tighten the sheet metal screw to secure the corner of the bezel to the cowl. Repeat this procedure for the other upper corner. Now

tighten both bottom screws, using the same techniques described previously.

E) Repeat STEP 3-D for the PASSENGER side.

STEP 4: TAILLIGHT BEZEL ASSEMBLY INSTALLATION

A) Insert the DRIVER and PASSENGER taillight bezel assemblies in the respective hole cut-outs in the rear body cowl and check for overall fit. (You may have to file or sand the cut-out area edges slightly to insure adequate clearance.) Align both bezel assemblies in the hole cut-outs and temporarily tape into place. Step back a few feet from the cowl and insure that the overall horizontal and vertical alignment matches on both sides. (You may want to take some reference measurements from the inside edge of the bag well and the bottom edge of the cowl to confirm alignment.)

B) Once you are satisfied with the bezel alignment you are ready to drill the four mount holes. Starting on the DRIVER side and using the bezel as a template, drill a 1/32" hole in the cowl at one of the upper corners. Insert a black 1/8" x 3/4" sheet metal screw about 3 threads into the hole. DO NOT TIGHTEN AT THIS TIME. Repeat this procedure for the opposite lower corner and then do the same for the remaining two corners.

C) Repeat STEP 4-B for the PASSENGER side.

D) You are now ready to permanently fasten the taillight bezel assemblies to the rear cowl. DO NOT OVER-TIGHTEN THE SCREWS, ESPECIALLY IN THE FLEXIBLE PLASTIC COWLS. Starting with the DRIVER side bezel at the upper mount holes, push in on the bezel so that it is tightly against the cowl and hand-tighten the screws. Repeat these procedures for the lower mount holes.

E) Repeat STEP 4-D for the PASSENGER side.

You are now ready to proceed with the Wire Loom Installation Instructions

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STEP 1: INITIAL PREPARATION

A) If you haven't already done so, remove the POSITIVE and NEGATIVE connections from the battery or battery pack.

B) Raise the front end of car and set it securely on safety jack stands. (NOTE: Insure that the car's safety brake is locked "ON" and the rear wheels are blocked to prevent it from rolling backwards.)

D) Position the PUSH / PULL SWITCH TEMPLATE in the recessed area of the DRIVER side beverage holder. Center punch for the hole location and then drill a 3/8" diameter hole. (To insure adequate clearance, the switch should be located on the left or right hand side of the recessed area, as indicated on template. If you want the switch located on the right side of the recessed area, simply flip the template over.)

YOU ARE NOW READY TO LAY OUT THE WIRE LOOM

STEP 2: LAY OUT WIRE LOOM

It is suggested that you remove the PUSH / PULL switch from the wiring harness to facilitate easier installation of the wire loom.

A) Starting in the battery/engine compartment on the DRIVER side of the vehicle, position the wiring harness with the two taillight wires going towards the rear of the car. Following the golf car

YAMAHA – 15663/15707 ^{Page 5}

QTY DESCRIPTION

2 Headlight insert assemblies

2 Taillight insert assemblies (*)

1 Wiring harness with push/pull switch and fuse holder (*)

16 1/8" x 3/4" black sheet metal screws (for headlight & taillight bezels)

10 Plastic cable ties, 11-1/2" long

1 Installation Manual with templates

(*) In complete kits only!