Tusk Compact Control Switch Installation Video

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Tusk Compact Control Switch Installation

If you need to hook up the Tusk compact control switch to your headlight, but you are not sure how to do this, you are in luck. Our detailed instructional video will walk you through how to hook up the Tusk compact control switch to your headlight. Trust us to have the answers and instructions you are looking for.

Transcription:

Hi I'm Justin from rockymountainatvmc.com and today I'm going to show you how to hook up the Tusk compact control switch to your headlight.

The tusk compact control switch can be used as a universal switch to run headlights turn signals and horn, but it's primarily designed for and used on the Tusk enduro lighting kit. We’re going to start by installing the switch to the handlebar.

The first thing you need to do is make sure you have room on your handle bar; you may need to move to kill switch or levers a little bit, in order to allow room for the switch. We're going to slide the little rubber grommets into the back side of the switch. This will keep the switch tight to the handlebar, keep from sliding around. Then we're going to install the front part of the switch and install the screws in the back. Then using zip ties or existing zip ties that are already on the handlebar were going to run the cable along the bottom of the handlebar to the front of a motorcycle.

Now let's look at the wires coming out of the switch. You'll notice five wires running to the connector, that connector plugs into the enduro lighting kit wiring harness and runs the turn signals and horn. In this video were going to focus on the three wires used to control the headlight. It's important to note that these three wires are going to be used to tap into the motorcycles existing headlight wires. Not the enduro lighting kit wiring harness. The reason for this is because most headlights pull a lot of power and most bikes don't put out enough power through the battery power source to run the headlight. It's important that the headlight remains connected to the bikes headlight power source. All we're doing is tying the control switch into the existing wiring.

Now let's look at the motorcycles headlight wiring. This is the Yamaha WR and its pretty typical of most motorcycles. You'll notice two wires running from the motorcycle into the plug, ones a positive and ones a negative. On the other side of the plug you'll notice three wires ones the negative again and then you have two positive wires one for high beam and one for low beam. You'll notice the power wire, coming from the bike, is only feeding one of these wires its typically the low beam. Most bikes come with the dual filament high and low beam bulb but they usually only power the low beam. With the compact control switch, we can switch between high and low beam so that we can use both.

Using this illustration, I'll show you how it's done. Here I show the positive and negative wires coming off the bike and high low negative wires running to the headlight. Here I'm showing how the three wires from the switch should be spliced into the bikes headlight wires, the positive lead from the bike is redirected into the black wire, on the switch, the white wire from the switch is directed into the low beam, on the headlight, and the blue wire into the high beam. Notice the negative or ground wire from the bike to the headlight is left alone.

So when the bike is started the power is redirected into the black wire on the switch. When we turn the switch on low the power is directed out the white wire, to the headlight, and when we turn the switch to high it’s directed out the blue wire to the high beam.

It's important to note that not all bikes come with dual filament bulbs; an XR400 is a good example. Without an aftermarket headlight it doesn't have a high, low option, so you would only hook up the low beam wire.

Now we can start tying in the switch by cutting the power wire from the motorcycle. We’re going to tie this power wire into the black wire on the switch, by using a quick connect splicer or a female connector that can be crimped on or soldered on. In our case, we're going to solder it on.

Now I'm stripping the insulation off the power wire, so I can install the connector. Once the wire is stripped, I will put the connector in place and solder it to the wire. If you choose not use solder. You can use a connector that will crimp to the wires. These connectors can be found at any hardware or automotive store.

Now, I am cutting the high and low beam wires running to the headlight. Once the wires are stripped, I will install the connectors. Make sure none of the metal from the connectors is exposed, because you don't want them grounding out on the motorcycle and damaging anything. If your female connectors don't completely cover the metal connection, use heat shrink tubing or tape to insulate the connection.

With all the connectors in place, I can plug the switch wires in. I'll plug the black wire to the bikes power source, the white wire to the low beam and the blue wire to the high beam. Inspect your work and if everything looks right, start the bike and test your light. You should be able to turn the headlight off, to low and to high.