EXCALIBUR YAMAHA DRIVE2 LED Light Kit Instruction Manual
- June 13, 2024
- EXCALIBUR
Table of Contents
LED LIGHT
YAMAHA
LIGHT KIT
YAMAHA® DRIVE2®
INSTALLATION INSTRUCTIONS
YAMAHA DRIVE2 LED Light Kit
INCLUDED:
Front and Rear lights
Wiring harness
12 Push nuts
Zip Ties
Rocker switch
TOOLS NEEDED:
3mm Allen wrench
10mm wrench
Rotary cutting tool
Sandpaper
Power drill
3mm Allen wrench
Rotary cutting tool
15/32” Drill Bit
NOTE:
Professional installation is recommended. If you choose not to have this
product installed by a professional, we highly recommend that you exercise
caution, care and patience when installing this product as it involves
drilling holes into your cart’s body. Professional installation is
recommended. If you choose not to have this product installed by a
professional, we highly recommend that you exercise caution, care and patience
when installing this product as it involves drilling holes into your cart’s
body. Professional installation is recommended. If you choose not to have this
product installed by a professional, we highly recommend that you exercise
caution, care and patience when installing this product as it involves
drilling holes into your cart’s body.
STEP 1
Switch the key to the OFF position. Place TOW/RUN switch to TOW. It is not r
batteries but you do need to disconnect the main negative.
OFF position. Place TOW/RUN switch to TOW. It is not required to remove the
equired to remove the batteries but you do need to disconnect the main
negative.
STEP 2
A) Remove Yamaha® Emblem and set screw, then remove the cup holder insert and
save the hardware for later. With the cup holder detached, remove the three
push rivets in the console.
Emblem and set screw, then remove the cup holder insert and save the hardware
Emblem and set screw, then remove the cup holder insert and save the hardware
for later. With the cup holder detached, remove the three push rivets in the
console. for later. With the cup holder detached, remove the three push rivets
in the console.
*NOTE: Use a small screwdriver to push centre in to release rivet. B)
There is one push rivet located in each Front Fender Well which will need to
be removed. C) Remove the final 6mm screw holding the cowl on and then unplug
both headlights.
Keep track of all removed hardware, you will need it later.
STEP 3
To Remove the factory cowl, use a small screwdriver to press in and release
the clips.
STEP 4
Place the cowl on a flat surface and use something to prevent scratching.
Remove factory headlight push nuts by gently prying them off with needle nose
pliers to avoid damage.
Remove Headlight. STEP 5
Mount new LED headlight through the cutout using supplied push nuts.
Use a deep well socket that fits push nut to seat the push nut *REPEAT process
on the opposite side.
NOTE: If your cart did not come with factory headlights, follow
instructions enclosed on templates. STEP 6
Remove all push rivets securing floor mat to the vehicle. Remove floor mat.
Remove the brake adjustment access panel. Retain All.
STEP 7
Using a 15/32” drill bit, find a desired location on your dashboard to mount
your rocker switch for the lights. Ensure the location is free of obstacles
and will not affect cup holder re-attachment. STEP 8 – HARNESS INSTALL
From the battery compartment, route wiring harness behind the battery pack
forward along the brake cables to the brake pedal assembly.
Pull headlight wiring from pedal assembly to front of cart but leave brake
switch hookups in pedal assembly. Route wiring harness through dash to mount
hazard rocker switch and USB port. Route tail light wiring to the rear of the
cart.
Loosely secure with zip ties until all lights have been installed.
IMPORTANT: Route wiring harness in such a way to prevent it rubbing
against or being pinched by moving parts such as suspension, belts, or
muffler.
RED connectors should be aligned to passenger side, white for driver’s side.
STEP 9
At the headlight, plug in the 3-pin connector for the headlights. Red
connectors go to the passenger side, white connectors for the driver’s side.
STEP 10 – REAR TAIL LIGHT INSTALLATION
A) Remove inner Fender Well by removing 5 push rivets.
B) Disconnect factory tail light wiring harness from tail light and remove
tail light.
STEP 11
Mount tail light through the cutout using supplied push nuts. Reinstall inner
fender well removed from STEP 10. Repeat process on opposite side.
NOTE: Use deep well socket to help seat the dimension on push nut fully.
STEP 12
Feed the tail light harness through the back of the cart. Attach rear tail
light wire harness as shown. Secure wire with ties.
STEP 13 – BATTERY CONNECTION
IMPORTANT: The cart’s battery pack configuration will determine how the
wiring harness is connected to the battery pack.
If your cart is equipped with SIX 8V batteries, a 16V to 12V voltage reducer
is recommended. In this case, you will connect the voltage reducer across TWO
of the 8V batteries and then connect the wiring harness to the appropriate
connections on the voltage reducer.
NOTE: Use a multimeter to ensure you are connecting to no more than 16
VOLTS to avoid damage to the light kit.
INSTALLATION COMPLETE