I need some advice please. My EZGO’s brake lights are acting up – sometimes they work, sometimes they don’t. It’s pretty clear the brake pedal light switch is to blame, but I’m stumped on how to replace it. Driving around without reliable brake lights is a no-go, especially in the evenings. Has anyone tackled this before?
Response
I ran into a similar headache with my EZGO RXV not too long ago. I swapped out the old switch for an OEM EZGO brake switch designed for external brake light activation. It was surprisingly straightforward – no need for complex wiring or messing with relays. Just attached it to the pedal assembly, connected the wires, and voilà! It’s a neat solution that gets rid of those unsightly foot pads or the hassle of controller-driven outputs. Hope this points you in the right direction.
Solutions that worked for users
| Solution | Success Count | Cost (USD) | Time (Minutes) |
|---|---|---|---|
| OEM EZGO Brake Switch Installation | 1 | $30 | 60 |
| Adjustable Bump Stop | 1 | $10 | 30 |
| Separate Brake Light Installation | 1 | $50 | 90 |
| Custom Component Retrofit | 1 | $70 | 120 |
1. OEM EZGO Brake Switch Installation
Detailed Steps:
- Identify the Correct Switch: Ensure the OEM EZGO brake switch you purchase is compatible with your golf cart model. Compatibility is key to a seamless installation.
- Access the Pedal Assembly: Safely lift or tilt your golf cart to access the underside where the pedal assembly is located. Ensure the cart is securely supported before starting your work.
- Remove the Old Switch (if applicable): If replacing an existing switch, carefully disconnect it, noting how it’s installed for reference when installing the new one.
- Install the New Switch: Attach the new brake switch to the pedal return stopper bracket. Most models have pre-drilled holes for this purpose. Use the screws provided with your switch for a secure fit.
- Wire the Switch: Connect the red leads from the new switch to the brake light circuit. Pay close attention to the wiring diagram provided with your switch to avoid any mistakes.
- Test Your Work: Before putting everything back together, test the brake lights to ensure they activate when the pedal is pressed. Adjust as necessary.
Handy Tips:
- Battery Disconnect: Always disconnect your golf cart’s battery before starting electrical work to avoid shocks or shorts.
- Use Dielectric Grease: Applying a bit of dielectric grease on the electrical connections can prevent corrosion and ensure a longer-lasting repair.
2. Adjustable Bump Stop
Detailed Steps:
- Gather Materials: You’ll need an M10x70mm bolt, a corresponding nut, and washers.
- Position the Bolt: Determine the optimal position for the bolt to prevent tire contact with the brake light switch. This might require some trial and error.
- Install the Bolt: Drill a pilot hole if necessary, then screw the bolt into place. Use washers to adjust the height and ensure a snug fit.
- Adjust as Needed: Test the cart’s braking to ensure the new bump stop doesn’t interfere with normal operation. Adjust the nut on the bolt to fine-tune the stop position.
Handy Tips:
- Regular Checks: Make it a habit to check the bump stop periodically for any signs of wear or loosening.
- Lubrication: A drop of thread-locking fluid can prevent the bolt from loosening over time due to vibration.
3. Separate Brake Light Installation
Detailed Steps:
- Select the Right Light: Choose a brake light that can be mounted independently and is compatible with your cart’s voltage.
- Mount the Brake Switch: Securely attach the brake pedal pressure switch to the pedal using self-tapping screws, ensuring it’s positioned to activate with pedal pressure.
- Wire the Light: Connect the light to the battery pack, considering the use of a voltage reducer to protect against overvoltage. Follow the wiring diagram carefully.
- Secure and Protect Wiring: Use cable ties and protective loom to secure the wiring under the cart, preventing damage from debris or movement.
Handy Tips:
- Voltage Considerations: If your cart is 48v, tapping into two 8v batteries for 16v can work, but monitor for any signs of light or battery wear.
4. Custom Component Retrofit
Detailed Steps:
- Source Components: List all necessary parts for the retrofit, including microswitches, cover plates, springs, and bolts. OEM parts ensure compatibility and reliability.
- Assemble the Components: Follow the factory setup as a guide to assemble your components. This might involve some custom fabrication or adjustment.
- Install and Wire the System: Install the assembled components onto your golf cart. Wire the microswitch to manage both braking and parking functions, simplifying your wiring harness.
- Test Thoroughly: Test the brake lights in various conditions, including with the parking brake engaged, to ensure everything functions as intended.
Handy Tips:
- Documentation: Keep a record of part numbers and the steps taken for future reference or maintenance.
- Consult Experts: Don’t hesitate to consult with a golf cart mechanic or dealer for advice on parts and installation.