ATV lighting kits are popular aftermarket accessories for quads. They add turn signals, a horn, rearview mirrors and a brake light (if your machine doesn’t already have one). One of the primary reasons people choose to install a lighting kit is to make their machine street legal. Please note that it is your responsibility to determine what your local laws are and if the Tusk ATV horn and signal kit allows your quad to meet those requirements.

A Polaris Sportsman ATV with the Tusk Lighting Kit Installed

Installing the Tusk ATV Lighting Kit

The ATV horn and signal kit is designed to provide a quality setup at a more affordable price than competing products. It includes the following components:

  • Wiring harness
  • LED front and rear turn signals
  • Flasher relay
  • Horn
  • Hydraulic brake switch
  • LED taillight / brake light (if your quad doesn’t already have one)
  • Handlebar end mirror
  • License plate mount
  • License plate light (if your quad doesn’t require a brake light as part of the kit)
  • Control switch

While there may be a lot of components in this kit, installation is easy, and we have a video walkthrough to accompany this written guide.

Please note that for the machine chosen in the video, recessed turn signals are used. However, we also sell a kit with flush mount turn signals if you prefer them. This tutorial demonstrates how to install both types.

The installation process varies slightly depending on the machine. This demonstration is on a Polaris Sportsman 550 EFI, but your quad may require minor differences in the kit’s installation.

What You Need to Begin

Tusk ATV Horn & Signal Kit with Recessed Signals

Of course, the first thing you’ll need is the lighting kit. After that, with a few standard tools on hand, you’ll be good to go.

Open-End Wrench Tusk Deep Socket T-Handle Wrench Black Permanent Marker
Wrenches Socket Wrenches Marker
Green Tape Measure Yellow Electric Drill Tusk 6 in 1 Screwdriver
Tape Measure or Ruler Drill Phillips Screwdriver
Cutting Pliers
Cutting Pliers or Similar Tool

  1. Install the wiring harness.
    1. Remove the quad’s seat. Remove the front cargo rack. This allows you to gain access to the battery.
    2. Removing the Front Cargo Rack

    3. Take out any necessary bolts and remove the side panel. Remove the cover piece underneath the headlight.
    4. Removing the Cover Piece Underneath the Headlight

    5. Route the wiring harness, positioning it in a location where it will not rub against any moving parts or be exposed to heat. The easiest way is to run it alongside the existing wiring harness. If you are unsure which part of the wiring harness goes to the front and which goes to the back, look for the two pink wires. They go in the back.
    6. Routing the Wiring Harness

  2. Install the license plate bracket and light (or taillight/brake light).
    1. The Tusk horn and signal kit is designed for quads that already have headlights. However, not all ATVs have taillights complete with a brake light. If your machine already has a taillight/brake light, you won’t get another one – just an LED license plate light and bracket. If your kit does come with a taillight/brake light, it will mount to the bracket and will also serve as the license plate light.
    2. Mount the taillight or LED light to the license plate bracket first. Run the wires through the center hole of the bracket.
    3. Running the Wires Through the License Plate Bracket’s Center Hole

    4. If you are installing a kit with an LED license plate light, you must also run the wires through a flat washer and nut. The nut screws on to the light. Make sure that the light bulb is facing down (onto the license plate bracket) before you tighten the nut with a wrench. If you are installing a kit with a taillight/brake light, you will secure it using screws on either side of the light.
    5. Pick a location to install it onto the machine. There are several options you can choose, but this tutorial demonstrates the installation to the rear bumper crossbar. In this case, place the P-clamps on the rear crossbar. Bolt the license plate bracket to the P-clamps. Make sure it’s centered before you tighten it down.
    6. Positioning the License Plate Bracket

    7. If you have the license plate light, use the black and yellow wire lead to connect the light to the harness. Connect the clip to the three-pronged plug. Run it down toward the license plate bracket. Be careful where you run them to ensure that they avoid possible heat damage or abrasion.
    8. Connecting the Clip to the Three-pronged Plug

    9. Connect the red lead from the light to the black lead from the harness. Connect the black lead from the light to the yellow lead from the harness.
    10. Wiring Diagram for the License Plate Light

    11. If you have the taillight/brake light, connect the clip from the harness to the three-pronged plug that is attached to the taillight. Next, you need to install the supplied brake switch onto your machine using the following steps. This allows the taillight to operate as a brake light.
    12. The Brake Switch

    13. Clamp the supply line to the rear master cylinder. Remove the stock banjo bolt.
    14. Removing the Stock Banjo Bolt

    15. Install a crush washer onto each side of the brake line fitting. Install the hydraulic brake switch. Tighten it down. Now that you have installed the brake switch, you will need to bleed your brakes.
    16. Connect each lead coming from the switch to the pink leads coming from the rear of the harness.
    17. Wiring Diagram for the Brake Switch

    18. If you’d like, you can purchase an additional brake switch to install on your front master cylinder, allowing it to activate your brake light as well. This step is optional. Please note that there are two types of Tusk hydraulic brake switches: one for Nissin brakes (10mm × 1.25 thread) and one for Brembo brakes (10mm × 1.00 thread). If you choose to install an additional brake switch on the front master cylinder, plug the leads to the red and black leads on the front of the harness.
    19. Wiring Diagram for the Front Brake Switch

  3. Install the signal lights.
    1. When you order your Tusk horn and signal kit, you have the option to choose from flush mount or recessed turn signals. Regardless of which style of turn signal you choose, it’s important to choose a highly visible mounting location. Double-check your measurements so that you only have to drill once. (This is especially important with the recessed turn signals.)
    2. If you have flush mount turn signals, run the wires through the double-sided sticky tape. Peel the inner side of the backing off. Stick it to the backside of the light. Pick the mounting location. Drill the hole for the wires using a ¼” drill bit. Run the turn signal’s wires through the hole you’ve drilled. Clean the mounting surface. The cleaner it is, the better the turn signal will adhere to the plastic on the machine. Peel the outer side of the backing off. Stick the turn signal to the quad. Repeat this process for the three other flush mount turn signals.
    3. Peeling the Outer Side of the Backing

    4. The recessed signal kit is supplied with a ¾” spade drill bit to mount the signals properly. Use it to drill the mounting hole. Since it is a large hole, make sure it is exactly where you want it to be and that there is enough room on the inside of the plastics for the rubber grommet to sit properly inside the drilled hole.
    5. Drilling the Hole for the Recessed Turn Signal

    6. Remove the rubber grommet from the turn signal and install that in the hole. Make sure it is pushed in all the way. Insert the turn signal (wires first) into the hole. Align it so that the word Top is at the uppermost part of the light. Repeat these steps for the other recessed turn signals.
    7. Inserting the Turn Signal into the Hole

    8. Run the orange and black wires to the rear left blinker. If you have recessed signals, connect orange to black and black to white. If you have flush mount signals, connect orange to yellow and black to black.
    9. Wiring Diagram for the Rear Left Turn Signal (Recessed)
      Wiring Diagram for the Rear Left Turn Signal (Flush Mount)

    10. Run the blue and black wires to the rear right blinker. If you have recessed signals, connect blue to black and black to white. If you have flush mount signals, connect blue to yellow and black to black.
    11. Wiring Diagram for the Rear Right Turn Signal (Recessed)
      Wiring Diagram for the Rear Right Turn Signal (Flush Mount)

    12. Repeat the process for the front turn signals using the same steps. The colors of the wires will match up in the same way.

  4. Install the control switch.
    1. Install the two rubber grommets on the backside of the switch. Find a suitable spot for the control switch on your handlebars. This could require moving some things around to make enough room. Install the back piece. Secure it into place with the provided screws.
    2. Finding a Spot for the Control Switch

    3. Run the wires down to the harness. Depending on your machine, you may need to remove screws on the headlight housing in order to gain access to run the control switch’s wires down the handlebars.
    4. Running the Control Switch’s Wires to the Harness

    5. The five-pronged plug will connect to the clip coming from the harness. Locate the yellow wire on the harness and connect it to the yellow wire coming from the control switch. The black wire (or ground) from the switch plugs into the black wire coming from the harness.
    6. Wiring Diagram for the Control Switch

  5. Install the horn and flasher relay.
    1. The horn comes with a mounting bracket. You can bend it if you need to (depending on where you choose as the horn’s mounting location).
    2. There are several locations where you can choose to mount the horn. It doesn’t matter exactly where you choose as long as it is away from moving parts and somewhere that will stay clean and dry. If you choose the same location as done in this tutorial, you’ll mount it using one of the radiator mounting bolts. It will first need to be removed.
    3. Removing the Radiator Mounting Bolt

    4. Run the red and green spade terminals coming from the harness to your chosen mounting location for the horn and install them. It doesn’t matter which wire attaches to which terminal – it will work either way. Then you can mount the horn. For example, if you’re installing it in the same location as done in this tutorial, you must reinstall and tighten down the radiator mounting bolt.
    5. The Mounted Horn

    6. The flasher relay plugs right into the clip coming from the harness with the red and blue wires. Once it’s connected, you can choose to mount it however you like. Some people choose to use Velcro on the backside. Others zip-tie it to the machine. Either way works fine.
    7. Plugging in the Flasher Relay

  6. Connect the lighting kit to power.
    1. For most machines, the shorter battery leads will be used to connect the wiring harness to the battery. For the machines with the battery up front, there are extra-long battery leads to reach to the front of the machine. The leads plug in to the clip located at the rear of the harness with the red and yellow wires.
    2. Run the leads to the battery. With the longer leads, you can follow the same route you used for the wiring harness. Connect those leads to the batteries – red to positive and black to negative.
    3. Wiring Diagram for the Battery

    4. Now that your lights are installed and the wiring harness is connected to the battery, test out all of the lights to make sure they are operating properly. Turn on the turn signals and check both front and rear. Make sure the license plate light or taillight is functioning properly (including working with the brakes if it’s a taillight). To finish your test, hit the horn button.
    5. If you have any problems, double-check the wiring. You can also check the five-amp fuse at the rear of the harness.
    6. Five-amp Fuse at the Rear of the Harness

  7. Finish up by installing the rearview mirror in the bar end and putting things back together.
    1. Insert the rearview mirror into the bar end. You may need to cut a hole in the grip in order to gain access to the bar end. Tighten down the mirror to secure it in place. Some machines will have an existing bolt you can use to mount the mirror.
    2. The Mirror Installed

    3. Use zip ties to secure all of the new wiring. You can generally just zip-tie the harness to the stock harness. Use cutting pliers (or a similar cutting tool) to cut off the excess tape of the zip tie. Start at the front with the two turn signals and work your way back. Don’t forget to tie up the wires underneath the fenders to avoid any contact with the exhaust or tires.
    4. The Wiring Harness Zip-tied to the Stock Harness

    5. When you reach the rear of the harness, you may notice two unused pink wires if your ATV already had a taillight or brake lights. You can just tie those up with the rest of the harness.
    6. The Pink Wires Zip-tied with the Rest of the Harness

    7. Reinstall the front rack, the side panels, the cover piece underneath the headlight, and the seat.
    8. Reinstalling the Front Rack

Conclusion

Now you’re ready. Your quad is set to go with turn signals, a license place bracket (and light), rearview mirrors and a horn. Go ride!

If you don’t already have a lighting kit to install, pick up the Tusk ATV horn and signal kit from Rocky Mountain ATV/MC today!

Technician Disclaimer