How To Install A Tusk Enduro Lighting Kit Video
How To Install A Tusk Enduro Lighting Kit
If you need install a Tusk Enduro Lighting kit, but you are not sure what to do, you are in luck. Our detailed instructional video will walk you through how to install a Tusk Enduro Lighting kit. Watch our industry expert as he to installs a Tusk Enduro Lighting kit. Trust us to have the answers and instructions you are looking for.
Hi. I'm Eric from RockyMountainATVMC.com and today I'm going to show you how to install a Tusk Enduro Lighting kit.
The Tusk Enduro Lighting kit comes complete with wiring harness, turn signals, horn, brake switch, tail and brake light, folding mirror and control switches. Keep in mind that the installation will vary from machine to machine.
We're going to start with the main wiring harness and to do that we need to remove the seat and the tank and then we're going to move the headlight out of the way. We want to look for a safe wiring path. You want to make sure there's one, there's no change for abrasion or a chance they'll get melted. A lot of times the OEM harness takes a safe route and it may be the best route to follow.
As you're threading the harness through you want to make sure the plugs at the rear of the harness end up over the top of the air box. The plugs at the front of the harness need to be fed up towards the front of the machine, behind the headlight.
Next we're going to move on to the universal tail and stop light and you can mount this several ways. You can use the existing mounts on your fender like we've done or you can just drill some holes and install some bolts. With the tail light assembly mounted, now it's time to attach the flush mounted signal lights. You want to start off by marking the location. Drilling a hole for the wires and then cleaning the surface well. Use a little Contact cleaner. Now we're going to put the sticky tape on the light itself. We're going to thread the wires through. Pull them tight and stick the light on.
Once you get the lights where you want them, pull the tail light assembly back off, thread the wires back up between the fender and the tail light assembly. You want to make sure that these wires aren't exposed to the rear tire. Now we're ready to permanently install the rear tail light assembly. You're going to feed the wires up through the sub-frame and then we're going to connect them. We're going to take the yellow wire from the left turn signal and connect it to the orange wire. Then we're going to connect both black wires from the turn signals to the black ground on the harness. Then we're going to connect the yellow wire from the right turn signal and connect it to the light blue wire. After we've got that, then we're going to plug in the main plug for the rear tail brake light.
Now it's time to install the rear brake switch. To do this we need to remove the rear brake line at the master cylinder and basically what we're going to do is we're going to replace this banjo bolt with a switch. I like to put a little fluid in. Try to purge some of the air out of the switch. Make sure and install the washers and then back onto the master cylinder.
On this machine there wasn't room to tighten the banjo bolt with the master cylinder on the bike so we had to remove it from the frame. We're going to bleed the brakes using the Tusk Hydraulic Brake Bleeder. Here we're removing all the guards that might be in your way around the caliper. We're taking off the reservoir cap so we can add fluid.
Then here we've installed the Tusk Brake Bleeder on the nipple on the caliper. Here we're topping off the reservoir and now you crack loose the nipple and slowly start to pump the pedal. Keep an eye on the fluid level in the reservoir. You don't want it to run dry introducing air back into the system. Continue this process until the fresh fluid has flushed the system and all the air bubbles are gone. Once you've achieved that, tighten the nipple. Check the fluid level and install the reservoir cap.
Now it's time to route the brake switch wires up along the subframe to the rear of the harness. We're using zip ties to secure it and also keep it away from the exhaust. They plug into the pink wires on the rear of the harness. Now it's time to install the control switch and the master on/off switch. Find a location on your bars for your control switch and your master on/off switch, route the wires down to the front of your harness. You want to make sure that you route them so they won't be pinched when the handle bars are turned from stop to stop.
Next we're installing our horn and we chose to install this on the triple clamp pinch bolts, so we needed to drill it out a little bit. It can be installed a variety of places. Once we have that installed it's time for the flasher relay. It does have a mounting hole on it but we chose to use double stick tape and just tape it to the back side of the headlight mask.
Now it's time for the front turn signals and we chose the kit with the hand guard mounted turn signals. You can mount these a couple of ways. You can mount it with the supplied brackets or we chose to mount it to the Tusk Wrap Around Hand Guards. We're going to install the turn signals inside the hand shields, tighten the screws and then mount it to the Wrap Around Hand Guards. Finish up by routing the wires down to the front of the harness.
If you purchase the kit with the mini stop turn signals you can mount them in a variety of ways. The easiest is to drill a hole in the head light mask. The wires would thread through the hole and you just tighten the nut to hold it there. Now everything's in place. It's time to start connecting the wires. The red and the green go to the horn. The yellow from the right turn signal goes to the light blue wire from the harness. The yellow from the left turn signal goes to the orange wire from the harness and the black wires go to the dual ground.
Now we will plug in the control switch. You'll notice three additional individual wires coming from the control switch. These are the wires needed if you want to run your headlight through the new switch. Refer to the control switch instructions. Black is the head light powered into the switch. White is the low beam power coming out of the switch and blue is a high beam power coming out of the switch.
Now we're going to connect the yellow and black wire to the main on/off switch and then we will plug in the blinker relay. In the harness we've made an allowance for a front brake switch. This is optional and can be used by purchasing and installing an additional Tusk Brake Switch to the front master cylinder.
Now it's time to hook up the battery. We offer two kits. One for machines with batteries and one without. If you have a battery on your machine you're going to use a supplied pigtail and hook the red to the positive, black to the negative terminal. For machines without a battery you're going to use this battery pack. You'll need to find a suitable location. We like to air box. It's attached with double sided sticky tape, so you'll need to clean an area so it'll stick.
We like the air box because it protects the battery pack a little bit from the elements. Now that the power source is squared away, it's time to connect it. Then we're going to test the system. Let's start by turning on the main power switch. We have a tail light, front and rear blinker, the horn and the brake light. If everything works OK, it's time to start putting the bike back together.
We'll start behind the head light. We'll tie the harness up. Put the head light mask on and then we're going to work back down the backbone of the frame and we're going to make sure the harness is tight against the frame rail, the subframe, the hand guards. Now we're going to throw the side panels on, the tank and the seat.
To finish it up we're going to install the Tusk Dual Sport Folding mirror. You can mount this either above or below the bars. Some people like it below so you can see around your shoulder. Either way, you can fold them up out of the way when you're not using them. Just check over the bike one more time, make sure that the wiring isn't interfering with the steering and then you're ready to ride.