‘87 Sun Classic Repower - Lights

[Penningtonjeff]

Hi, repowering a 1987 Sun Classic, welcome help with the original cart lights. Converting to 48V, Alltrax, and Dakota Lithium batteries. I built a new assembly for the drivetrain electrical components, and am close to having that bench tested and the motor doing what it’s supposed to. Had to give up on the original FNR key switch, as it caused a voltage drop under load. Installing new key and FNR switches.

MY ASK: No luck with the lights currently. If you have experience getting the lights working, would love to hear about it. Likewise any documentation or diagrams on the wiring harness for the headlights, turn signals, brake lights. Found a G1 service manual in another thread, but that doesn’t address the Sun Classic lighting that I can see.

Thanks,
Jeff

[Penningtonjeff]

Never did anything like this before, so we startedby transcribing the Alltrax wiring diagram to cardboard, placing the components on the cardboard and drawing wires where they needed to be. We then laid everything out on aluminum plate, including the batteries. Mocked up wire runs, then attached components and made wires. Had to do a bunch of troubleshooting because we made some wrong connections, turned out it was easy to do this when we pulled the assembly out and worked on it outside the cart. Now trying to integrate into the cart, first run and drive. Lights are important, as this’ll get used at night by my kids pretty quickly.

Can’t post links yet (new member) so here are some more attachments.