Tusk Compact Control Switch Installation | Enduro Lighting Kit
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- Опубликовано: 7 сен 2024
- www.rockymount... - Instructions on wiring and mounting the Tusk compact control switch so you can run your motorcycle headlight on high beam, low beam, or off. The switch can be used on about any motorcycle but comes with the Tusk enduro lighting kit. add blinkers, horn, and brake light with the tusk enduro lighting kit! Available at rockymountaina... !
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/ @rmatvmc
great how-to, oldie but a goodie, still relevant today. well done.
Not only does Rocky Mountain sell excellent products at the best price, but these instructional videos put them over the top with customer service! A+
thanks for this! wouldn't have been able to understand my switch without it! you guys rock!!!!
Idotproof video!
I don't speak english, I don't do mechanics and I don't have an idea about electricity BUT after watching this video I am confident to go on with this stuff and fix some light on me new bike!
GREAT job man!!
Thanks!
@octaneorange - this kit is designed to run off the rechargable battery (included in some kits) or off the bike's existing battery (that is charged from the bikes system). If the bike didn't come with a battery and charging system and you are trying to convert it, I am not certain how to help you. It will most liekly depend on the regulator/rectifier you are using and how much power is feeding the battery. The small tusk battery pack may not be able to take the full power from the rectifier.
Rocky Mountain ATV MC ..... will you be able to recommend a solution for the 2017 YZ450FX? How can I get a headlight working with this application and can I still use this switch to run it? Thx
Great video, also if your going to add a headlight kit like this to a bike that did not previously come with one you can run power directly off the battery with a fuse 👍🤙
What do you mean. How . Explain please.
@@swishersweets2155 Dude, it's two wires. What do you mean how? There's positive and negative.....
Off the battery in the Enduro kit? Was wanting to toss on am aftermarket light and run that way but wasn't sure if the little battery would be enough power or if I should get the kit without battery and run a larger mc battery? Bike is db-X18
Use the positive wire from the pair of leads intended for your front brake switch, run a negative from your battery. Take the positive to your switch cluster and then you'll be able to switch your high and low beam from your selector switch.
Yeah it looks pretty slick and the way we customized the rear under fender for tail kit + turns. Only thing I'm debating, you think the 12v5ah battery will be good for complete tusk street legal kit + 30w headlight. I will add another in line fuse for light but I'm going to wire both to battery w/ quick connect so when battery dies, can hookup 12v charger w quick connect ...battery is in airbox and will be sealed w/ leads coming out for access for easy disc.+hookup. Don't think wires should warm up if using bigger gauge. Lastly, am I understanding right, stock stator would not be enough for this setup. (kickstart) again, thanks for all your help!
+Mike Klumb The stock stator no. It doesn't provide a high enough output to power such a unit. I know Trail Tech makes some high output stator kits though, so that might be an option? I'm not sure if its available for your year machine? The battery pack idea seams fine to me. Updating the wires to thicker AWG wire wouldn't be a bad idea with the headlight an all.
@Elb0WsInNUMBers - yes. All you are doing is redirecting the power. Most bikes have dual output stators. I wanted to make sure that people are using the output intended for the headlight, not the output that keeps the battery charged. If your bike has a new stator or a modified stator with a single output all converted to DC, you don't need to worry about getting the right lead from the stator. However the switch can still direct the power to the headlight.
if you have the lighting kit can you just take the included battery pack to run the headlight?
Great help. Would have been even better if you included this information with the switch.
Totally agree, why the hell weren't these instructions included on my wiring diagram and why aren't these damn switches waterproof at this price???
The on/off switch is marked "engine stop". Total cheese. Can't Enduro guys get better products? Sheesh...
once that the power from the bike goes into the switch does it have energy to turn signals to? thanks
Thanks so much!!
Thanks for checking it out!
My bike has an ignition lock. Is it possible to connect the system to it?
- get a 12 volt tester and see what the gray wires are for. I am not familiar with that bike. I would assume the black is ground.
I'm sure it's possible but it would be a trial and error install. You are going to have to do cutting and splicing of wires to get it to work so i would say it's not recommended.
I have a 2005 KTM 525 exc. I would like to know how to properly connect the hi/Lo switch since the headlight runs off the stator not the battery, I prefer to keep it this way. Also is the hi/PO switch have 12 volt current from the battery?? Cannot mix AC/DC power.
did you figure this out? i can only get my high beam to come on
Thank you very much helped me so much great video
+jerry That's what we like to hear. Thanks for commenting.
@cow productions You could wire this switch up on your bike. The only issue you might have is whether or not your current headlight has a high beam or is a dual filament bulb. You might also have to invest in an aftermarket headlight. Let me know if you have any other questions.
i have a baja designs light and im only getting the high beam. how do i get the low? i have the same switch setup as your using here
I’m using this switch on an ebike. What do I use for a ground to the switch?
Thanks for the video. I just bought an XR 400 with what looks like the Tusk Dual Sport kit installed (also electric start). I am in the process of trying to figure out the setup but would love to know what you would recommend I do to setup a hi/low lighting. Thanks for your reply.
hi i need it for my grizzly 550 eps, because want to install turn lights, horn and offroad lights, but dont know where to take power ? from battery or headlight power, or cigarette lighter? please help me
I bought the tusk brake light kit and a polisport basic headlight. I'm only running the brake light, horn, and headlight. I can't figure out how to wire the headlight with the switch. My bike didn't have a headlight from the factory. I have a blue white and black wire off the switch. Can't figure out how to wire the headlight.
Did you get it figured out? I’m having the same issue on my 2015 350XCF
@Rocky Mountain ATV MC How do I wire the 3 headlight wires to the Polisport MMX Headlight? I'm not an eletrician, and the instruction manual is very vague.
Is it possible to trickle charge the lithium ion battery from the original stater even if it is wired to power the headlight from the stater? - 1996 Ktm exc (already had headlight/taillight powered by stator, no battery stock but added lith ion got lighting kit).
So what do you do if your bike does not have a headlight and you’re adding one? Bike in question is a 2015 RMZ450
I have a question, Putting this kit onto a TTR 250 2006, and I took off the head light and coming off the bike lead I have a black cable, and 2 gray cables. After the connector everything is the same, Just confused on the 2 gray wires. Thanks in advance.
The headlight seems to only work if I pair one of the high/low beam wires to the ground and connect the other to the low/high off the switch. Any advice?
So will my off on switch from the bike still operate off on and the tusk switch operates the low high beam
I have a crf230f and in australia they have a factory fitted light, low beam only and no on/off switch will this work on my bike and if not how can I wire a on/off switch.
My 2004 USA version of the CRF230F had a low and high beam. Consider looking at a Honda parts website and ordering the USA version. Many of our parts website have complete diagrams showing every single part of the bike and you might be able to determine if it'll work for you, like... Does that headlight have three wires or is it the same as what I already have...
Is it possible to wire this into the stock indicator/wiring loom on the wr250f?
Does the control switch have to be installed for the brake light switch to work?
I would run it to the battery.
the black wire doesn't seem like its pulling enough power to send through the hi and low switches to power the light. I have connected the low conection(light and switch) to pos and the high to neg. Conected the light ground to the switches black wire. Off=high
Low=low
High=high
I am stumped... I would like off to equal off lol. Also this is a 10w max led headlight where low is normal and high is extra bright. Dual bulb jfg racing led. Help please.
Will this kit work with a 2004 Polaris Sportsman 400 ATV?
I have a 2019 Yamaha YZ450FX. I bought the tusk kit for the bike. I understand how to wire the headlight but hoping you know if there is a switched power source so I don't have to connect directly to the battery. I'm running a WR headlight with a Cyclops LED light that will draw 30 watts.
Ever figure this out? I’m trying to install a headlight to my yz250 2T, confused on how to get the head light running.. buying a h4 socket, then wire that straight to the tusk harness head light wires?
Hi I'm working on a 2005 WR450F and I'm having trouble connecting my headlight up. I can't connect it this way shown because whoever did the last wiring job soldered everything together and it had to be ripped out in order to put this new lighting system in. Any ideas?? I have three wires from the OEM wiring harness loose but they're blue yellow and black. Also, the light bulb plug itself has three connecters on it that are green, brown, and black, and everything works besides the headlight.
Why isn't this in the Tusk install instructions...
I did exactly as video pictures described but now when I turn on signal lights to the left the rear right signal light comes on and vice versa when turning right signal light on. Also my hand lever brake does not work but foot brake does. I installed micro switch to hand brake lever. All worked fine until I wired as described in the video. Something weird going on!!!
+Donald McCoy Sounds like theres a little mix up with just connecting the blinker wires, maybe double checking them in the harness you'll be able to diagnose it? Video: ruclips.net/video/_DoJ7IpImKU/видео.html
Could be you mixed up the wires to the (front) hydraulic brake switch? Maybe check there to. If that doesn't do the trick, let me know what color wires from the harness you have going where? We'll see if we can get this figured out..
Anyone know if these drain the battery while bike is off?
Can you buy a kit without a light, and put a different light on?
Getting power to the switch, and all the wires. However the bulb doesn't come on
I just got the same switch but i missing a wiring diagram or something? can someone help me out and tell me which wire goes where or let me know where i can find a wiring diagram??
Does this switch have a hi beam indicator ??
+therejectzz69 Negative
So.... if i want to retrofit a Bi Xenon HID kit, how would i use this switch to actuate the solenoid in hi if the hi and low are separate circuits?
You may want to refer to their website for specific wiring instructions. It looks like the high and low beam wires split when they go out to the factory machine connector and that is where you'd want to split and take the high to the high coming out of this switch. Same thing for the low, that would run to the low coming from this switch.
I have a Honda Crf450x 2008 and mine has 3 wires on both sides witch one do I cut? Thank you
depends on how the stock light operates.
What if you don't have existing headlight?
What if I don’t have an original headlight?
Will the tusk compact control switch power the polisport head light?
Yes, this switch can be used with the Polisport headlight.
Rocky Mountain ATV MC WOW super quick response thanks! Will be ordering more parts from you guys!
What is the bike didn’t come new with a head light
how do you install the horn!!!!!!!!!!!!!
I dont understand why you tap into the harness side of the plug instead of just cutting up the bulb-socket wiring. That would make much more sense as to keep the original wiring unmodified. But either way, this will get you going.
I have this complete light kit installed and all are working off a 12v5ah battery. 04 crf150f kick start. Kit didn't come w headlight so have an aftermarket headlight on that has hi/lo (4wire:blue, white,Brown,green). Didn't realize the 3 wires (blue/white/black) from the harness(control/switch) aren't powered. any advice? Would ultimately like to hook up to same battery as other lights
+Mike Klumb Ok. So your (blue/white) wires are for your hi/lo beam. The (black) wire coming out of the compact control switch is your power. However you plan to power your headlight, you would just need to tie your (black) wire into that (wire). Powering your control switch. Let me know if that works.
You're the man! I was going off black as neg blue as lo white as high. Thank you thank you! We have light! GREATLY APPRECIATED along with the fastest response time. Great customer service hard to come by these days, will recommend to everyone.
+Mike Klumb You're welcome my man! It was a good question. Glad you got it working! Should be a fun little bike with that headlight
+Rocky Mountain ATV MC I did the same thing but no power. I have a blue white and two green wires that go to the head light. I connected the black to the two green wires and the white with white and blue with blue. why isn't it working?
+Mike Klumb hey Mike, I'm also trying to run an aftermarket light with the rechargeable battery, how did you get power to the switch? thanks!
What are the wire sizes? I need to buy some wire crimp connectors...
Scott Hair The wires are a 16awg. Let us know if ya have any other questions. Thanks for checkin out our video!
Rocky Mountain ATV MC Thanks for the quick reply and for the video! One more question. How well will these connectors stand up against weather (rain) and washing the bike. Should we wrap up with electrical tape after connected?
Scott Hair The male and female wire connectors hold up really well to be honest. You can get some heat shrink to cover the connectors to give it that clean look and to keep them protected from the elements. Tape is fine to though. It just gets a little sticky and grimy over time.
Rocky Mountain ATV MC Sorry this is a dumb question as I've never done this before, but would you recommend putting one longer heat shrink cover across both male and female connectors after they are connected? So it seals off the connection plus the crimped areas? I would think so but just checking. Would it need any kind of silicon sealant on the crimped sides too?
Scott Hair Yes, that would appear a lot nicer in my opinion. The silicon sealant wouldn't hurt honest if you have some, but not needed. Heat shrink works great. Thanks for the comments!
Hello, all the smoke escaped from my bikes wiring. It had a different lighting kit on it when I bought it and I have since ordered yours as well as the front factory wiring harness. (2001 KTM 400 EXC RFS US) the new KTM harness had only two wires for the headlight a brown and a white wire. The "smoked" harness headlite connector had three all black wires. I am not having much trouble installing your enduro lighting kit but the wiring of the Compact Control Switch is confusing. Can you please help. Thank You
"smoke test" humorous term thrown about by mechanics diagnosing electrical when something bad happened. what did you end up cooking and how did you fix it?
How would you add head light if the bike didn't have one to begin with?
depends on bike
I did everything . High beam low beam work but the off switch does not work it remains in low beam. What might be the problem ?
Gokul Kavaturi Hi. Its hard to diagnose the issue without having the bike. I would refer you to our Enduro Lighting Kit Installation Video: ruclips.net/video/nflgfeqxRW8/видео.html
Let us know if you have any other question. Thanks for watching!
Rocky Mountain ATV MC thanks for replying. took the switch apart and put it back together and its working fine now.
Gokul Kavaturi Hey anytime! Good to hear ya got it working. Happy Riding!
@@GokulK2 same issue as you. You just reassembled the switch itself? And it was no longer fault? Also was were your connections and power source in your case?
@@cmc2375 its been some years but as i remember just taking it apart and putting it back together fixed it. connections same as the diagaram. power source from headlight battery connections
hi I am currently trying to install the head light on my bike. how ever its on a crf150f and it does not have a stator and I am trying to run it off the tusk battery. I cant find out how to install it can you help me
+crazyruski777 That replacement battery pack is designed to power the small LED lights for your turn signals, taillight and horn. Customizing it to power an aftermarket headlight would be up to your own modifications to make it work. It's not designed to power a an aftermarket headlight
+Rocky Mountain ATV MC so basically I'm boned and spent a bunch of money for no reason lol. went you telling mike klumb the black wite leads to the power. any recommendations for me to get the head light running??
+crazyruski777 How many wires are coming out of your aftermarket headlight? (colors?) The kit is still going to work. You would just need to figure out a power source to feed your control switch (black) wire. It is do-able, our buddy "Klumb" was able to diagnose it. but our kit just wasn't designed that way. Let me know what wires are coming out of the headlight and we'll go from there..
+Rocky Mountain ATV MC there are 4 wires. a white and blue then two green that connects together. I connect the whip with white blue with blue and black with green with bullet connectors. no go.. I'm stumped tried a couple varations and Nothing.
Where are you grounding the headlight to? I don't think you have the headlight grounded.
Does the black wire from the switch go to the wiring harness or another part? I'm having trouble connecting it to this www.amazon.com/gp/product/B07C6XZPV7/ref=ppx_yo_dt_b_asin_image_o03_s00?ie=UTF8&psc=1
The problem I’m having is on my 2016 yzf450fx It doesn’t have a Head light What would be the best solution for my problem
Shane Jetton .... yeah I have the same problem. What can a guy do??
I used a drone battery to run the head light only and purchased an after market switch so it's completely separate from the bike's battery (YZ250FX). I mounted the drone battery into a fender bag on the back and ran my wires along the chassis to the after market light switch. I tried to hook it up the OEM bike battery but I don't think it had the amps to run all the light properly, The headlight would come on but not bright at all. The drone battery works great and will last a few days before your have to put it on the drone battery charger.
I have followed this correctly.i got a bad switch.
I have a 1999 TTR250. My stock headlight connector has 1 back wire and 2 grey??? Im trying to hook up the Tusk Enduro kit, to my new Polisport Halo Headlight. Everything else works, but im not sure how to wire the headlight(im a total wiring noob). Also the stock headlight switch(singe beam) has 2 yellow wires and turns both the stock headlight and tail light on) should I do anything with these? I wont be using the stock tail light.
If you are removing the stock headlight and switch assembly along with the tail light, i wouldn't worry about either of those yellow wires. As for the wiring for your headlight you'll simply need to figure out what each of those wires is doing. I would recommend using a test light and connecting it to a good ground source and then checking each of those wires for power. My guess would be one or both of the grey wires are your power source and the black is the ground but i'm not positive. Once you locate a power run that up through the switch like the video shows and then back down to the headlight through the high and low beam wires. The only things you need from your stock headlight wires are one ground and one positive wire. If you have further questions please let me know
Thanks for the response, I got it all figure out though. Working great, will be buying more parts from Rocky Mountain ATV in the future!
MaHan05
Sounds great! Thanks for watching!
OriginalRob what did you do to fix it? Havin the same issue
Hey guys! I was posting on the enduro kit thread, but now I have a headlight specific question. 2004 WR450. I watched the video for splicing the control switch to hi/low beam. My headlight was different (no connector plug in the middle, just a yellow, white and blue wire coming from the harness to a three way plug into the back of the headlight) so I ran cut the yellow and ran it from the bike to the black switch wire. I then spliced the white switch wire to the yellow in the headlight and the blue switch wire in the blue into the headlight. Left black alone running from the bike to the headlight. In the other thread, you guys said this looked right.
Anyhow, I just fired it. No headlight when off as to be expected. Turn it to lo beam and the headlight comes on. Turn it to hi beam and there is no difference. Stays the same. Any thoughts?
Think I might have found the problem. Looks like both the blue and yellow wires run to the SAME portion of the bulb plug. It is a three socket plug. ONly two have metal connectors inside (low beam I am guessing and ground). My guess is a new socket at the end of the wires going into the headlight is needed. I would post a pic but apparently I cant upload from my Mac.
Quinn Posner Yep, most stock headlights will only have a single filament bulb or only a low beam. It's pretty popular for guys to just purchase an aftermarket headlight and that would fix your problem, unless you wanted to try and find a different socket that could run a dual filament bulb
Rocky Mountain ATV MC A new $3 socket took care of the problem.
so how can i power a headlight , if my dirtbike has no battery yet?
It depends on which bike you have but you may have to get a higher
output stator in order to produce enough power to run a headlight. In
most cases a bikes stock stator doesn't produce enough power to power a
headlight on top of everything else so i would start there. Some bikes
that have a lighting coil can power a headlight while the bike is
running without having a battery on the bike.
Damn , fast response. Thanks.
Hello Justin how about some after the purchase tech support please? I sent an e-mail to the address provided by RMATVMC but have not received an answer. Thank You
Make sure you sent your email to tech@rockymountainatv.com and include your order number in the subject line and we'd be happy to look at what's going on with your switch.
Thanks!
My bike doesn’t have an existing headlight it’s a 11’ kx250f and I’m trying to make it street legal
I have a yz450 somebody for the love of god help me wire this headlight