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MadJax 05-235 Installation Instructions Manual

Storm body kit
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Part # 05-235*
Storm Body Kit
Installation Instructions
ITEMS INCLUDED
Box 1
Box 2
Bag Well
Left and Right Front Fenders
Trunk Cover
Left and Right Rear Fenders
Hardware Pack
Center Front Hood Panel
Storm Light Kit
Center Panel Rear Body
Front Grille
Rear Bumper
1
Hardware Kit
See below
Hardware Kit Reference Guide
*HDW ITEM #
DESCRIPTION
M4 Torx Head
1
Self-Tapping
Screw (Part# N/A)
M5 Sheetmetal
2
Screw
(Part# N/A)
M5 Clip Nut
3
(Part# N/A)
Aluminum
4
Black Rivet
(15058G6)
Aluminum
5
Rivet
(10570G12)
Aluminum
6
Black Rivet
(71055G01)
Stainless Steel
7
Rivet
(10570G11)
8
8" Wire Ties
*See callouts in illustrations, i.e. HDW 7
TOOLS NEEDED
Drill and drill bits
Hole Saw kit
#2 Phillips Screwdriver
Side Cut Pliers
T20 Torx Bit
T25 Torx Bit
SIZE
QUANTITY
6.3*16*16MM
23
5*16MM
19
N/A
19
5*20*16MM
10
6.3*16*16MM
4
4*23*12MM
13
5*20*16MM
6
N/A
10
10mm Wrench
Rivet Tool

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Summary of Contents for MadJax 05-235

  • Page 1 Part # 05-235* Storm Body Kit Installation Instructions ITEMS INCLUDED TOOLS NEEDED Box 1 Box 2 Hardware Kit Drill and drill bits 10mm Wrench See below Bag Well Left and Right Front Fenders Hole Saw kit Rivet Tool Trunk Cover...

  • Page 2: Vehicle Preparation

    The MadJax Limited Warranty only covers defects in materials and workmanship, and does not cover damage due to ® improper installation. If you are having difficulty installing this product, contact your Authorized MadJax Dealer. ® Be sure to read all instructions before starting installation.
  • Page 3 REMOVING THE REAR BODY STEP 3 Electric Models – If the vehicle has a FNR switch mounted to the body, remove it by drilling out rivets, and retain switch for later reinstallation. Also remove and retain the charge port, taking note of wiring connections before removal. Gas Models –...
  • Page 4 STEP 4 Drill out four (4) rivets (Item 1) securing the seat hinges to the body. Retain the hinges. Drill out the eleven (11) remaining rivets (Item 2) that secure the body to the vehicle. See Fig. 1. *Note: Two rivets on both sides* Fig.
  • Page 5 STEP 8 Unplug the headlights if equipped and remove the cowl. If the vehicle has a light kit, remove and discard the wiring harness. It will not be compatible with the Storm light kit. STEP 9 Remove the front bumper and support bracket and discard. *Note: With the cart completely disassembled, be sure there are no old rivets left in the vehicle frame where they were drilled out.
  • Page 6 STORM LIGHT KIT HARNESS INSTALLATION *Note: Reference Schematic Wiring Diagram on p. 27* STEP 10 Locate the headlight end of the harness and route under the driver’s side of the vehicle (Figs. 1 & 2) and up into the battery well or engine compartment (Fig. 3). Refer to Schematic Wiring Diagram on page 24. The rear should be routed along the top of the frame rail (Fig.
  • Page 7 FOR ELECTRIC VEHICLES STEP 11 ( FOR GAS VEHICLES SKIP TO STEP 16) Mount the supplied voltage converter to a flat metal surface. Route the battery jumper harness toward the main battery positive and main battery negative, but DO NOT connect to the battery yet. Once routed, secure the harness with wire ties. See Fig.

  • Page 8: Relay Connection

    RELAY CONNECTION STEP 14 RELAY KEY 1. Connect the BLACK Wire 1/8” female spade connector from the battery jumper harness into the relay. 2. Connect the RED Wire (in-line) 1/8” female spade from the light kit harness to the relay. The end connector of this line will not be used. 3.
  • Page 9 REVERSE LIGHT CONNECTION (FOR ELECTRIC VEHICLES) STEP 15 The light kit harness is provided with two plugs for the reverse switch jumper, along with two different length reverse switch jumpers to accommodate varying vehicle configurations. A. For vehicles with the FNR Switch in the kick panel of the rear body: Use the LONG reverse switch jumper (Item 1).
  • Page 10 Unplug the orange wire (Item 3) from the FNR switch and replace it with the 1/4” female spade connector (Item 4) Switch of the reverse switch jumper. Plug the 1/4” male spade connector of the reverse switch jumper to the orange wire of the stock vehicle harness.
  • Page 11 FOR GAS VEHICLES ( FOR ELECTRIC VEHICLES SKIP TO STEP 20) STEP 16 Relay & Converter are not required for Gas Plug the fused RED/BLACK female connector from the battery jumper into the RED/BLACK male connector from the light kit harness. Battery Jumper Harness Light Kit...
  • Page 12 STEP 18 Remove the stock harness plug from the bottom pin of the reverse switch under the shifter mechanism. Plug 1/8” female spade connector of the reverse switch jumper (Item 1) to bottom pin of the reverse switch. Plug the 1/8” male spade connector of the reverse switch jumper to the 1/8”...
  • Page 13 INSTALLATION CONTINUED (ALL MODELS) STEP 20 Determine the desired location for the USB Charger on the vehicle instrument panel. Ensure the location is free of obstacles and will not interfere with reinstallation of the front cowl to the instrument panel. Use a 1-1/8” paddle bit to drill into the instrument panel at the desired location.
  • Page 14 STEP 8 STEP 24 Mount indicator assembly to steering column using clamps provided and tighten. Run indicator harness down the steering column and insert through the instrument panel. STEP 25 Attach turn signal cover to indicator assembly. Attach steering column cover over steering column, securing the indicator harness.
  • Page 15 STEP 7 STEP 7 STEP 27 The turn signal handle has a secondary, 2-position rotary switch for auxiliary 12V lighting. There is one common negative wire and two positive wires to supply power to two (2) different sets of auxiliary lighting. Additional wiring and lighting not included in this kit.
  • Page 16 FRONT COWL ASSEMBLY STEP 8 STEP 28 Cover worktable with something soft to prevent scratching body panels. Place the hood assembly upside down on worktable. !!ALL HARDWARE IN PLASTIC BODY PANELS SHOULD BE HAND TIGHTENED!! STEP 9 STEP 29 OVERTIGHTENING FASTENERS CAN RESULT IN STRIPPED THREADS. Install four (4) clip nuts (HDW 3) to hood section as shown below.
  • Page 17 STEP 6 STEP 30 Install front grill to center hood and fenders using five (5) self-tapping M4 screws (HDW 1). Tighten with a T20 Torx socket. Fig. 2 STEP 7 STEP 7 STEP 31 Install the headlights to the cowl assembly using three (3) self-tapping M4 screws (HDW 1) per headlight. Tighten with a T20 Torx socket.
  • Page 18 STEP 8 STEP 32 Install the assembled front cowl to the vehicle. Use the retained front strut hardware to help hold the cowl in place. Be sure the cowl is tight to the instrument panel secure it using seven (7) rivets (HDW 6). Secure the cowl to the vehicle frame using two (2) rivets (HDW 7).
  • Page 19 REAR BODY ASSEMBLY STEP 6 STEP 34 Install four (4) clip nuts (HDW 3) on each of the rear side body panels as shown below in Fig 5. Align tabs on bag well into slots on side body panel and secure using four (4) M5 screws (HDW 2) per side. Tighten with a T25 Torx socket.
  • Page 20 STEP 8 STEP 35 Align tabs on side body panels into slots on rear bumper as shown in Fig 7. Secure using three (3) M5 screws (HDW 2) into the clip nuts (HDW 3) as shown in Fig. 6. Tighten with a T25 Torx socket. Secure both sides with three (3) M4 self-tapping screws (HDW 1) using a T20 Torx socket.
  • Page 21 STEP 6 STEP 36 *Note: If installing on a gas vehicle or a vehicle with FNR on the kick panel, a hole will need to be cut into the front panel for the shifter/ wiring harness, using the embossment on the inside of the panel as a drilling guide.
  • Page 22 STEP 7 STEP 7 STEP 38 Install the assembled body to the vehicle. Secure front panel to floor using five (5) black aluminum rivets (HDW 4) and side panels to vehicle frame using four (4) aluminum rivets (HDW 5) as shown in Fig. 10. Use retained rear bumper hardware to secure rear bumper to vehicle frame through mounting holes on rear of bumper.
  • Page 23 STEP 9 STEP 39 Plug taillights into light kit harness. STEP 9 STEP 40 Install rear trunk cover to bag well. Align bottom hooks of trunk cover into slots on bag well as shown in Fig. 1. Pivot trunk cover up, pressing pins into rubber grommets installed on the bag well as shown in Fig. 2. *Note: For 250/300 seat kits see next page for alternate installation method.* Fig.
  • Page 24 *Note: Trunk cover door cannot be removed Installing Rear Trunk Cover with Genesis 250 /300 Seat Kit once 250/300 seat kit has been installed.* Before installing the trunk cover you will need to remove the bag well bracket from the seat frame. Place the bag well bracket over the rear bumper, insert the trunk cover between seat kit vertical support tubes on bagwell bracket and rear bumper.
  • Page 25 VEHICLE ASSEMBLY STEP 8 STEP 42 Reinstall the seat hinges using provided stainless steel rivets (HDW 7) as shown in Fig. 1. Put in floor mat. Fig. 1 STEP 8 STEP 43 Reinstall rocker panels using provided 4 black aluminum rivets (HDW 4), spacers, & factory bolts/hardware as shown below in Fig.

  • Page 26: Installation Complete

    ® marks, and products are only for purposes of identifying golf carts with which this MadJax product is compatible. MadJax products are aftermarket parts and are not original equipment parts. MadJax is not connected to, affiliated with, sponsored by, or endorsed by either Textron Innovations, Inc., Ingersoll Rand, Inc., Yamaha Golf Cart Company, or any of their parent or subsidiary companies.
  • Page 28 STORM SERIES...