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Old 08-22-2018, 09:58 AM   #1
sporta
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Join Date: Aug 2018
Location: Sun Valley, NV
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Exclamation 77 HD Cart wiring

Hey all,

Been working on getting our 77 3 wheel HD cart ready for the trip to Burning Man...and time is quickly running out lol. I found a wiring diagram that Crash Test Dummy posted on a thread for a 74 cart (think that was it...read so many they all blurring now). I modified it to reflect what I was thinking of doing on our cart. All lights will be LED's including the tail/brake lights. My plan was to run the head and tail lights off a rocker switch on the dash (no high beams or turn signals needed) and I found a universal brake switch to control the brake lights. His setup appears to be for an electric cart, with mine being gas, I assume the 3 way switch is not needed...

I want to be able to run the lights only when the key is on...what is the best way to do this? Just pull a wire off of both solenoids to the fuse block and then run the remainder off the battery (horn / power outlet)? Any help would be greatly appreciated. I have attached both his original diagram and my modified one. I really need to get cracking on this as we leave next Tuesday LOL.

Thanks in advance

Steve
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Old 08-22-2018, 11:25 AM   #2
Lochlin
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Default Re: 77 HD Cart wiring

Bunch of issues here. Do you have two solenoids are your cart or just one? I am not aware of HD ever using two but some carts do use two (one for F and one for R) so I am not sure with the '77.

Electric Club Cars used two solenoids, one for primary circuit (on and off with the key switch) and one for just the drive circuit (on and off with the accelerator pedal). In his case, yes, he could wire to the primary solenoid. In your case that won't be an option.

The issue is that the key switches on these carts don't actually switch any current on and off. They just enable current to be turned on and off when the accelerator micro-switch is activated. If you put a volt meter on your switch with it turned off you will naturally see no volts. When you turn the switch on you will still no volts until the gas pedal is pushed. Hence the issue. If you wire to the switch your lights will indeed only come on when the key switch is on but the accelerator will have to be depressed. This isn't practical as your lights will go off when slowing / stopping. Most folks just go with a toggle and wire straight to the battery.
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Old 08-22-2018, 12:06 PM   #3
sporta
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Default Re: 77 HD Cart wiring

Quote:
Originally Posted by Lochlin View Post
Bunch of issues here. Do you have two solenoids are your cart or just one? I am not aware of HD ever using two but some carts do two (one for F and one for R) so I am not sure with the '77.

Electric Club Cars used two solenoids, one for primary circuit (on and off with the key switch) and one for just the drive circuit (on and off with the accelerator pedal). In his case, yes, he could wire to the primary solenoid. In your case that won't be an option.

The issue is that the key switches on these carts don't actually switch any current on and off. They just enable current to be turned on and off when the accelerator micro-switch is activated. If you put a volt meter on your switch with it turned off you will naturally see no volts. When you turn the switch on you will still no volts until the gas pedal is pushed. Hence the issue. If you wire to the switch your lights will indeed only come on when the key switch is on but the accelerator will have to be depressed. This isn't practical as your lights will go off when slowing / stopping. Most folks just go with a toggle and wire straight to the battery.
Ok, that was going to be plan b...We will just have to make sure that the lights get turned off when not needed and use a large enough wire from the battery to the fuse block...the LED lights shouldn't be too much of a draw on the system, should it?

Thanks for the input :)

Steve
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