2006 G22 6 seat barn find

[wjrich100]

Hi All-
I just got a 2006 Yamaha G22 JU2-402xxx that has 2 rows of seats, not sure if the stretch was done by Yamaha or by someone later.
I have zero experience w golf carts, but have rebuilt motorcycles, car work, etc, so I have basic mechanical skills but nothing on carts.
So far, I've installed new batteries after de-rusting and repainting a lot of the battery and aft drive area. I'm now working on finding/fixing a short in the light harness which other than access to the dash light switch should be relatively simple. With new batteries the cart runs strong on level surface, drags a bit uphill. Steering gear seems in good shape; no leaks visible on the shocks; brakes are good. Replaced tires and rims with stock-sized (8x8.5) new from Tractor Supply Co.
As a newbie to this, I've got a couple of basic questions that the wiring diagram and parts book don't clearly identify (to me anyway).
What are parts 1,2 & 3 and what do they do? I know I've got a controller and a voltage reducer in there, but not sure what is what.

[Altster]

Never seen part 1 before.
Part 2 is the solenoid, main relay. This should "click" when turned to run.
Part 3 is the controller. Cpu of the car.

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[wjrich100]

Thanks.
Part #1 has me baffled.

[cgtech]

Part 1 is a 16v to 12v converter for the lights. Looks factory. It's not the best type, because it draws from only 2 batteries (which will eventually leave them unbalanced from the rest). A 48v to 12v converter is better.

Also, the cupholders pop out easy to get into the dash, just pinch & pull up.

[wjrich100]

Well everything is cleaned up and put together and the cart looks nice.

My last issue is to get the headlights working.

When turning on the light switch after installing and charging fresh batteries, the rear lights worked fine, but the front lights worked briefly (split second) before both bulbs blew.
Looking closely at the bulbs (originals were Trident 054703; 12v3030), it appears that the bulbs have 2 filaments- a slightly larger spring- like filament and a wire-like filament. The wire filament was broken; spring-like one was intact.

Yamaha dealer had a couple of replacement bulbs- same Trident bulbs, same number. I installed the bulbs, flipped the light switch on and immediately had the same reaction- bulbs lit then immediately burned out. Same result on examination- the smaller wire filament had been broken; larger spring filament appears intact. Tailights work fine.

The light wiring harness has an in line 10 amp blade fuse, and it is intact. I looked at a NOS light wiring harness at the dealer, and it's the same as I currently have on the cart to include a 10 amp fuse.

Don't want to invest in more bulbs until I can figure this one out- what am I missing?

The cart does have a voltage reducer (photo above). Is perhaps this not working properly? Cart was fully charged when all this happened. Ignition switch in "off" position, as the lighting harness seems to be hot all the time. Tow switch was on "tow" if that matters.

[cgtech]

Disconnect 2 wires from headlight socket & probe them with volt meter to see what voltage really is. Its gonna be too high, but we need to know how bad.

[wjrich100]

Will do. May be a couple of days before I get to it, but will report back.

Use voltmeter right at connection where bulb socket disconnects?

[cgtech]

Yes

[wjrich100]

Couldn't get a reading with voltmeter probes in the headlight socket, so cut the socket off and stripped about 1/4" from the green, black and yellow wires.
Picture shows reading from black/green wires. Got no reading from black/yellow or green/yellow.
Tail lights working fine.

[cgtech]

So, I'm thinking that blue voltage reducer in the battery area may be hooked up to 3 batteries, instead of 2 batteries.