MADJAX E-Z-GO Storm Body Kit Instruction Manual

E-Z-GO Storm Body Kit

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Specifications:

• Part #: 05-235

• Tools Needed: Drill and drill bits, Hole Saw kit, #2 Phillips
  Screwdriver, Side Cut Pliers, T20 Torx Bit, T25 Torx Bit, 10mm
  Wrench, Rivet Tool

• Hardware Kit Includes:

  • M4 Torx Head Self-Tapping Screw (23)
  • M5 Sheetmetal Screw (19)
  • M5 Clip Nut (19)
  • Black Rivet (10)
  • Rivet (4)
  • Black Rivet (6)
  • Rivet (8)
  • Wire Ties (10)

Product Usage Instructions:

Vehicle Preparation:

STEP 1: Make sure the key is off and the vehicle is in Tow Mode.
Disconnect the main negative battery cable.

STEP 2: Remove factory canopy, struts, and seat kit if
applicable, retaining all hardware for later installation.

Removing the Rear Body:

STEP 3: Drill out rivets securing the seat hinges to the body.
Retain the hinges.

STEP 4: Drill out rivets securing the body to the vehicle.
Unplug taillights if equipped.

STEP 5: Remove the body from the vehicle after disconnecting
taillights.

Storm Light Kit Harness Installation:

STEP 10: Route the harness under the driver’s side of the
vehicle and up into the battery well or engine compartment. Secure
with wire ties.

FAQ:

Q: Do I need to disconnect the battery when removing

parts?

A: Battery removal is not required, but it is recommended to
disconnect the main negative battery cable for safety.

Q: How many wire ties are included in the hardware kit?

A: The hardware kit includes 10 wire ties for securing
components during installation.

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Part # 05-235* Storm Body Kit Installation Instructions

ITEMS INCLUDED

Box 1
Bag Well Trunk Cover Hardware Pack Storm Light Kit Front Grille Rear Bumper

Box 2
Left and Right Front Fenders Left and Right Rear Fenders Center Front Hood Panel Center Panel Rear Body

Hardware Kit See below

TOOLS NEEDED
Drill and drill bits Hole Saw kit #2 Phillips Screwdriver Side Cut Pliers T20 Torx Bit T25 Torx Bit

Hardware Kit Reference Guide

10mm Wrench Rivet Tool

*HDW ITEM #

DESCRIPTION

M4 Torx Head

1

Self-Tapping

Screw (Part# N/A)

M5 Sheetmetal

2

Screw

(Part# N/A)

3

M5 Clip Nut (Part# N/A)

Aluminum

4

Black Rivet

(15058G6)

Aluminum

5

Rivet

(10570G12)

Aluminum

6

Black Rivet

(71055G01)

Stainless Steel

7

Rivet

(10570G11)

SIZE
6.31616MM

QUANTITY
23

5*16MM

19

N/A

19

52016MM

10

6.31616MM

4

42312MM

13

52016MM

6

8

8″ Wire Ties

N/A

10

*See callouts in illustrations, i.e. HDW 7

1

MadJax® recommends 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 as it involves drilling holes into your bodywork. The MadJax® Limited Warranty only covers defects in materials and workmanship, and does not cover damage due to improper installation. If you are having difficulty installing this product, contact your Authorized MadJax® Dealer.
Be sure to read all instructions before starting installation. !!ALL HARDWARE INTO PLASTIC BODY PANELS SHOULD BE HAND TIGHTENED!!
VEHICLE PREPARATION
STEP 1
Make sure the key is off and the vehicle is in “Tow Mode.” Battery removal is not required, but it is recommended to disconnect the main negative battery cable.
STEP 2
Remove factory canopy, struts, and seat kit if applicable, retaining all hardware. Make note of hardware location for later installation.
2

REMOVING THE REAR BODY
STEP 3
Electric Models ­ If the vehicle has a FNR switch mounted to the body, remove it by drilling out rivets, and retain switch for later reinstallation. Also remove and retain the charge port, taking note of wiring connections before removal.
Gas Models ­ Remove and retain the FNR handle. Disconnect the choke cable from the carburetor and remove from rear body.
3

STEP 4

2

1

Drill out four (4) rivets (Item 1) securing the seat hinges to the body. Retain the hinges. Drill out the eleven (11) remaining rivets (Item 2) that secure the body to the vehicle. See Fig. 1.

Note: Two rivets on both sides

2 1

2

Fig. 1
STEP 5
Unplug taillights, if equipped, as shown below in Fig. 2.. Drill out two (2) rivets in bottom of bagwell, if equipped. See arrows in Fig. 3. Remove the body from the vehicle.

5 3

Fig. 2

Fig. 3

STEP 6

Remove the four (4) plugs (Item 3) in the bumper. Remove the screws and drill out two rivets (Item 5) on each side (4 total). See Fig. 3. Retain mounting nuts and bolts.

Note: If equipped with upgraded wide bumper, additional fasteners may need to be removed.

STEP 7

Drill out the nine (9) rivets (Item 1) that secure the front

1

cowl to the instrument panel. See Fig. 4.

Fig. 4 4

STEP 8
Unplug the headlights if equipped and remove the cowl. If the vehicle has a light kit, remove and discard the wiring harness. It will not be compatible with the Storm light kit.
STEP 9
Remove the front bumper and support bracket and discard.
Note: With the cart completely disassembled, be sure there are no old rivets left in the vehicle frame where they were drilled out. A good cleaning is also recommended, but be sure to disconnect the battery pack and be careful to avoid directly spraying the solenoid and controller with water. 5

STORM LIGHT KIT HARNESS INSTALLATION
Note: Reference Schematic Wiring Diagram on p. 27
STEP 10
Locate the headlight end of the harness and route under the driver’s side of the vehicle (Figs. 1 & 2) and up into the battery well or engine compartment (Fig. 3). Refer to Schematic Wiring Diagram on page 24. The rear should be routed along the top of the frame rail (Fig. 4). Red connectors go to the passenger side of the vehicle (Fig. 5). Secure with wire ties.

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5
For electric vehicles, proceed to step 11. For gas vehicles, skip to step 16.
6

Fig. 6

STEP 11

FOR ELECTRIC VEHICLES ( FOR GAS VEHICLES SKIP TO STEP 16)

Mount the supplied voltage converter to a flat metal surface. Route the battery jumper harness toward the main battery positive and main battery negative, but DO NOT connect to the battery yet. Once routed, secure the harness with wire ties. See Fig. 1.

STEP 12
Plug Red/black female connector (Item 1) from the battery jumper harness into the red/black male connector (Item 2) from the voltage converter as shown in Figs. 1 and 2.

1 2

Fig. 1

STEP 13
Plug the red/black male connector (Item 3) from the light kit harness into the yellow/black female connector (Item 4) from the voltage converter as shown in Fig. 2.

3
Battery Jumper Harness
4

Light Kit Harness
Voltage Converter

Fig. 2
7

RELAY CONNECTION
STEP 14

RELAY KEY
4 3
21

1. Connect the BLACK Wire 1/8″ female spade connector from the battery jumper harness into the relay.
2. Connect the RED Wire (in-line) 1/8″ female spade from the light kit harness to the relay. The end connector of this line will not be used.
3. Connect the YELLOW Wire 1/4″ female spade connector from the light kit harness to the relay.
4. Connect the RED Wire 1/4″ female spade) from the light kit harness to the relay.

VIEW OF COMPLETED RELAY CONNECTION
Voltage Converter

Battery Jumper Harness
8

Light Kit Harness

REVERSE LIGHT CONNECTION (FOR ELECTRIC VEHICLES)
STEP 15
The light kit harness is provided with two plugs for the reverse switch jumper, along with two different length reverse switch jumpers to accommodate varying vehicle configurations. A. For vehicles with the FNR Switch in the kick panel of the rear body:
Use the LONG reverse switch jumper (Item 1). Plug the LONG reverse switch jumper (Item 1) into 2-prong connector on the light kit harness (Item 2) shown. Route jumper along front of battery compartment and secure to the seat frame with wire ties.
1 2
9

Unplug the orange wire (Item 3) from the FNR switch and replace it with the 1/4″ female spade connector (Item 4) of the reverse switch jumper. Plug the 1/4″ male spade connector of the reverse switch jumper to the orange wire of the stock vehicle harness.

FNR Switch
4 3

B. For vehicles with FNR Switch in the instrument panel:
Use the shorter reverse switch jumper (Item 5) shown below. Plug the jumper into the 2-prong connector (Item 6) in the main light kit harness provided under front cowl.

6

5

6

Remove the switch from the instrument panel and route the reverse switch jumper out through the switch hole, securing with wire ties. Unplug the orange wire (Item 3) from the switch and replace it with the ¼” female blade connector (Item 4) from the reverse switch jumper. Plug the ¼” male blade connector from the reverse switch jumper to the orange wire from the stock vehicle harness. Replace the switch in the instrument panel.

3 4

10

STEP 16

FOR GAS VEHICLES ( FOR ELECTRIC VEHICLES SKIP TO STEP 20)
Relay & Converter are not required for Gas

Plug the fused RED/BLACK female connector from the battery jumper into the RED/BLACK male connector from the light kit harness.

Battery Jumper Harness

Light Kit Harness

STEP 17 REVERSE LIGHT CONNECTION(FOR GAS VEHICLES)
Use the LONG reverse switch jumper (Item 1). Plug the LONG reverse switch jumper (Item 1) into 2-prong connector on the light kit harness (Item 2) shown below. Route jumper along front of battery compartment, and secure to the seat frame with wire ties.
1
2

11

STEP 18
Remove the stock harness plug from the bottom pin of the reverse switch under the shifter mechanism. Plug 1/8″ female spade connector of the reverse switch jumper (Item 1) to bottom pin of the reverse switch. Plug the 1/8″ male spade connector of the reverse switch jumper to the 1/8″ female spade connector of the stock vehicle harness. (The larger 1/4″ spade connectors will not be used in this application)
1
STEP 19
Connect the RED WIRE 1/4″ male spade connector (one with in-line connector) from the light kit harness to the YELLOW WIRE 1/4″ female spade connector on the light kit harness. The two remaining female spades will not be used.
Battery Jumper Harness Light Kit Harness
Reverse Switch Jumper
12

INSTALLATION CONTINUED (ALL MODELS)
STEP 20
Determine the desired location for the USB Charger on the vehicle instrument panel. Ensure the location is free of obstacles and will not interfere with reinstallation of the front cowl to the instrument panel. Use a 1-1/8″ paddle bit to drill into the instrument panel at the desired location.
STEP 21
Install the USB Charger using the supplied hardware. Then plug the red and black 12V accessory connection from the light kit harness to the spade terminals on the back of the USB Charger (red to positive and black to negative.)
STEPP262
Put the supplied U-bolts behind the floor frame member next to the brake pedal. Align the brake switch bracket with the 90°flange facing the front of the cart and the switch button facing down. Make sure the four (4) threaded ends of the -bolts go through the slotted holes in the bracket and hand tighten the nuts. Do not fully tighten yet. Slide the bracket sideways so that the button of the brake switch is centered on the brake pedal arm. Slide the bracket down until the switch clicks. Then tighten all nuts.
STEPP263
Plug the two (2) bullet connectors from the brake switch into the corresponding connectors on the light kit harness. Secure all wiring so that it is away from moving parts. Tighten all wire ties to secure the harness.
13

STEEPP284
Mount indicator assembly to steering column using clamps provided and tighten. Run indicator harness down the steering column and insert through the instrument panel.
STEP 25
Attach turn signal cover to indicator assembly. Attach steering column cover over steering column, securing the indicator harness. Plug in 12 pin connector to light kit harness.
STEPP266
Attach horn to purple and black spade connectors from the light kit harness. Secure the horn to the vehicle frame under the front cowl using supplied hardware.
14

STEEPP277
The turn signal handle has a secondary, 2-position rotary switch for auxiliary 12V lighting. There is one common negative wire and two positive wires to supply power to two (2) different sets of auxiliary lighting. Additional wiring and lighting not included in this kit.
Auxiliary rotary switch
*Hazard Switch Installation: Using a 15/32″ drill bit, find a desired location on your golf cart dashboard to mount your rocker switch for hazard lights. Ensure your location is free of obstacles and will not affect dash reattachment.
Earth Load Supply
Spin Nut
15

FRONT COWL ASSEMBLY
STEEPP288
Cover worktable with something soft to prevent scratching body panels. Place the hood assembly upside down on worktable.
STEP 299 !!ALL HARDWARE IN PLASTIC BODY PANELS SHOULD BE HAND TIGHTENED!! OVERTIGHTENING FASTENERS CAN RESULT IN STRIPPED THREADS. Install four (4) clip nuts (HDW 3) to hood section as shown below. Install the left and right front fenders to the hood. Align the slots on the fenders with tabs on the hood. Secure with four (4) M5 screws (HDW 2) using a T25 Torx socket.
HDW
3
HDW
2
Fig. 1
16

STEPP360
Install front grill to center hood and fenders using five (5) self-tapping M4 screws (HDW 1). Tighten with a T20 Torx socket.
HDW
1 Fig. 2
STEEPP371
Install the headlights to the cowl assembly using three (3) self-tapping M4 screws (HDW 1) per headlight. Tighten with a T20 Torx socket. Note: The passenger side headlight has a red plug.
1 HDW Fig. 3
17

STEEPP382
Install the assembled front cowl to the vehicle. Use the retained front strut hardware to help hold the cowl in place. Be sure the cowl is tight to the instrument panel secure it using seven (7) rivets (HDW 6). Secure the cowl to the vehicle frame using two (2) rivets (HDW 7).
HDW
6

HDW
7

Fig. 4

HDW

7

STEP 393
Plug the headlights into the light kit harness.

18

REAR BODY ASSEMBLY
STEPP364
Install four (4) clip nuts (HDW 3) on each of the rear side body panels as shown below in Fig 5. Align tabs on bag well into slots on side body panel and secure using four (4) M5 screws (HDW 2) per side. Tighten with a T25 Torx socket. See Fig. 5.
HDW
2
HDW
3
Fig. 5
19

STEEPP385
Align tabs on side body panels into slots on rear bumper as shown in Fig 7. Secure using three (3) M5 screws (HDW 2) into the clip nuts (HDW 3) as shown in Fig. 6. Tighten with a T25 Torx socket. Secure both sides with three (3) M4 self-tapping screws (HDW 1) using a T20 Torx socket. See Fig. 7.
HDW
2
HDW
3
Fig. 6
HDW
1
HDW
1
HDW
1 Note: Underside shown repeat on opposite side
Fig. 7
20

STEPP366
Note: If installing on a gas vehicle or a vehicle with FNR on the kick panel, a hole will need to be cut into the front panel for the shifter/ wiring harness, using the embossment on the inside of the panel as a drilling guide. A 1-1/4″ hole saw or rotary cutting tool can be used.

HDW

Install the front panel of body to the side panels using four (4) M4 self- tapping screws (HDW 1)

1

using T20 socket as shown in Fig 8.

Fig. 8

STEPP367

HDW

HDW

2

3

Install two (2) clip nuts (HDW 3) to the inside of each side

panel as shown in Fig. 9. Use two (2) M5 screws (HDW 2)

and tighten with T25 Torx socket. Secure each taillight to

HDW

the assembled rear body using one (1) M4 self-tapping

1

screws (HDW 1). Tighten with T20 Torx socket.

Note: The passenger side taillight has a red plug.

Fig. 9
21

STEEPP378
Install the assembled body to the vehicle. Secure front panel to floor using five (5) black aluminum rivets (HDW 4) and side panels to vehicle frame using four (4) aluminum rivets (HDW 5) as shown in Fig. 10. Use retained rear bumper hardware to secure rear bumper to vehicle frame through mounting holes on rear of bumper. See Fig. 11.

HDW
4

Fig. 10

HDW
5
Note: Driver side shown. Repeat on opposite side

Fig. 11
22

STEP 399
Plug taillights into light kit harness.

STEP 490
Install rear trunk cover to bag well. Align bottom hooks of trunk cover into slots on bag well as shown in Fig. 1. Pivot trunk cover up, pressing pins into rubber grommets installed on the bag well as shown in Fig. 2. Note: For 250/300 seat kits see next page for alternate installation method.

Fig. 1

Fig. 2

23

Installing Rear Trunk Cover with Genesis 250 /300 Seat Kit

Note: Trunk cover door cannot be removed once 250/300 seat kit has been installed.

Before installing the trunk cover you will need to remove the bag well bracket from the seat frame. Place the bag well bracket over the rear bumper, insert the trunk cover between seat kit vertical support tubes on bagwell bracket and rear bumper. Align bottom hooks of trunk cover into slots on bag well. Pivot trunk cover up, pressing pins into rubber grommets installed on the bag well.
After you have the trunk cover installed, use retained hardware to secure bag well bracket to cart. Reattach seat kit.

*Trunk Cover shown without 250/300 seat kit bracket for clarity

STEPP461
Install the shifter or FNR switch to the rear body. – Electric vehicles will need to reinstall the charging
port and connect it to the battery pack. Using charging port as a template , drill out holes and fasten using the supplied rivets (HDW 6).
– Gas vehicles will need to reinstall the choke panel using retained hardware and reconnect the choke cable to the carburetor, making sure the choke operates freely.
24

*Gas model shown

VEHICLE ASSEMBLY
STEEPP482
Reinstall the seat hinges using provided stainless steel rivets (HDW 7) as shown in Fig. 1. Put in floor mat.

HDW
7
Fig. 1

STEEPP483
Reinstall rocker panels using provided 4 black aluminum rivets (HDW 4), spacers, & factory bolts/hardware as shown below in Fig. 2.

HDW
4
HDW
4 Note: Passenger side shown. Repeat on opposite side
Fig. 2
25

STEEPP484
Reinstall seat kit, struts, and canopy using retained hardware.
STEEPP485 Install red ring terminal from battery jumper to main positive terminal on vehicle battery and install black ring terminal from the battery jumper to main negative terminal on vehicle battery.

Electric

Gas

INSTALLATION COMPLETE
E-Z-GO®, TXT®, RXV®and S4® are registered trademarks of Textron Innovations, Inc. Club Car®, Precedent®, DS®, Onward® and Tempo® are registered trademarks of Ingersoll Rand, Inc. Yamaha®, Yamaha® Drive®, Drive2®, G-14®, G-16®, G-19®, G-22® and G-29® are registered trademarks of Yamaha Golf-Car Company. Any reference to Club Car®, E-Z-GO®, or Yamaha® or their associated trademarks, word marks, and products are only for purposes 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 to, affiliated with, sponsored by, or endorsed by either Textron Innovations, Inc., Ingersoll Rand, Inc., Yamaha Golf Cart Company, or any of their parent or subsidiary companies.
26

27

Schematic Wiring Diagram

STORM
SERIES
28

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