Lights and Horn quit on my 2003 EZGO

wingnut2000

I recently replaced my fwd/reverse assembly and the lights did work after I finished but noticed yesterday that the headlights and taillights all of a sudden quit as well as the horn. I don't think these are related? maybe coincidental that they went out a week after replacing the assembly. Any help would be great. I checked the three fuses on the driver side under the seat and they appeared to be ok.

BGW

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BobBoyce

If your 12V is from a battery tap, check your wires and fuse for that. It would be a seperate fuse from your main harness fuses. If your cart has a voltage converter to convert your main pack voltage down to 12V, check the plug(s) and wires at the converter, and any fuses on those wires. Get a voltmeter and check input and output leads for voltage and post those.

Bob

wingnut2000

got any pictures showing where these are?

kernal

Does this cart operate the lights with the key switch? Is there a green wire going from one side of the fuse panel to the positive connection on the center rear battery? How many black wires are connected to the negative on the rear passenger side battery?

wingnut2000

Yes,yes, 3

HarryT

On my 2005 the lights and horn are on one fuse. They both went out last week. I pulled one fuse at a time, tested it and put them back in. The last one I checked was not making contact at one end in the fuse block. I pushed it back in and presto, the lights and horn came back to life.
Harry

kernal

So this tells me this is a factory (OEM) light installation. They use the center rear and the passenger rear batteries as the 12v source for the lights/horn.The green wire is the positive to the fuse panel which is the bus for all the 12v positive connections on the accessories. The three black wires are: large one is high current for the drive system, smaller one goes to the charge receptacle and the smallest one is the negative (ground) for all the 12v accessories. I point all this out just in case you didn't know.

I agree this is probably unrelated to the F/R switch servicing. I think HarryT is on to something. First I would check the 12v connections. Tug on them because sometimes they look OK but are corroded/broken inside the insulation. Next I would take all the fuses out and put them back in to make sure they were seated correctly. Next I would install new fuses because because it's easy and cheap. After that it's time to break out the multimeter.

Does this cart have brake lights? If you are unsure look for 2 wires zip tied to the brake pedal arm. Do the brake lights work? If you have them they should work anytime you press the brake pedal. The cart does not have to be on. If they are present and work this can help you narrow down the problem.

Do you have a wiring diagram for the 12v harness?

wingnut2000

I took all three fuses out and looked at them and made sure they were seated nicely. Thanks for explaining the wiring kernal. Can I pick up new fuses at autozone or somewhere?

It does have brake lights and they are not working but I don't think they have ever worked under my ownership.

There is a red wire from the light wiring harness going to the fwd/rev assembly. maybe its not supposed to be going there. I don't know why it would?

kernal

Glass fuses correct? Auto parts stores should have them although mine have never had to be replaced (17 years) so I haven't looked for them lately.

For the brake lights make sure the wires come out on the other side of the kick plate (firewall) and are connected to the harness and not cut.

I can't address the red wire directly other than to say I think it's supposed to be there and connected to a micro switch. Is it red or orange? The micro switches have nothing to do with lights. I'm speaking from long time owner experience but I'm not a golf cart tech.

I can't look at my cart at the moment.

wingnut2000

yea glass fuses and red wire