So, a little ATV wiring…

What I gouged my hands up doing… installing winch control wiring on my ATV.


From the switch on the handle bars, down to a keyed hot to actuate the switch relay; I got that on a accessory wire that was under the front fenders.

Then winch main switch wires back along the inside of the frame to the relay box I put at the battery.

And that relay box turned out to be too big to fit where I wanted it next to the battery… (ALWAYS check your plans before running the wires! LOL )

Took apart the box, and sure enough it’s a wired set of relays, all bundled up stuffed in a water tight box… with twice the air space wasted..

I chucked the box ๐Ÿ˜‰ and the bundle fit perfectly in the battery compartment. 

THEN did it all over again;
running the hot wires from the battery foreward along the same path to the front bumper for the winch motor.

Whole thing only took about 4.5 to 5 hours, including reassembling the fenders… Yeah. Plus 1 hour before hand just chasing the accessory wires to begin with..  

FUN. ๐Ÿ˜‰

Easiest part was taking apart the front and taking the fenders off… actually amazed me how easy it is to get the plastic off this quad! (2009 Kawasaki Prairie 360)

And it is amazing, the owners manual says there are accessory wires at the rear, under the fender by the tool box (actually great, two sets, one constant power, and one keyed power!) But doesn’t mention the front set of wires.

And the service manual doesn’t mention Either set!  Except on the wiring diagrams, the rear set is marked.

EDIT; ok, I found the front set on the wiring diagrams in the service manual… It’s either the provided wires for the non-USA model speedometer,  or the non-USA and non-Canada Horn. (Really? A stock horn on an ATV? That’d be cool! 😆😎)

Given the location, and that it lacked a green signal wire for the speedometer,  I think it’s the horn wires.

Categories: Alaska-Life, ATV, Automotive Work, Modifications, Vehicles, Wiring, Wrenching

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One thought on “So, a little ATV wiring…

  1. AlaskaLinuxUser

    Nice work!

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