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MaxxTow Off-Road Light Bar Installation - 2016 Kawasaki Teryx4 800

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How to Install the MaxxTow Off-Road Light Bar on a 2016 Kawasaki Teryx4 800


Shane: Him I'm Shane with etrailer.com. Today you're going to be taking a look at, I'm going to walk you through the installation of the MaxxTow offroad LED light for your 2016 Kawasaki Teryx 4 800 side by side.What are some of the reasons you would add a light bar to an offroad vehicle like this A lot of reasons, a lot of people use these for riding at night. Adding an LED light bar is really going to help you see down that trail a lot better than just using the normal headlights on the side by side. A lot of other reasons, maybe you add a wench to the front and you're going to use or utilize that LED light to help you wench out your partner that maybe stuck down in the ditch or something like that. So LED light strips serve a lot of purposes for these offroad vehicles.Our light bar's going to be 31 and 1/2 inches long. It's going to give us two rows, 30 lights on top, 30 lights on bottom, 13,200 raw lumens and a 30,000 hour lifespan.

Now you're going to have, this is going to be a dual use beam. So in the center, we're going to have our spot beam. You'll notice the sides here, the lights look a little bit different. These are going to be flood beams. Your spot beam gives you a farther out distance look.

Your flood beam gives you more out to the side. So you're going to have flood beam on this side, flood beam on that side and your spot light in the center. So you're getting a pretty wide range of lighting for whatever trail you're on.It's going to have a durable black powder coated aluminum housing. Polycarbonate lens to help protect your lights on the front. You'll notice right back here on the back, there's going to be fins and this helps keep the light cool.

The light is adjustable. On the top of the leg here, where the leg meets the light there's little teeth. If you loosen the nut on each leg, you can adjust your light up or down depending on where you want to aim your beam.Now as far as the installation process on it, it's pretty simple. If you're going to mount like we did up here, it is going to require some longer bolts. The bolts that come in the kit are not going to be long enough because we had to go down through the frame rail on the inside.

So I'll recommend getting at least a three inch bolt, that's a quarter inch. You're going to get a lock nut for each one, a washer for each one, and just a regular nut for each one.As far as your wiring, where your light connects into the wiring harness that goes down to your battery. If you just want to be able to plug it in, if the light ever gets damaged, you can take it off and put a new one on and just plug it in, leave your existing wiring there. Then you'll need two spade connectors. If you want to hard wire it, I recommend getting heat shrink butt connectors and hard wiring those to the red and black wire from the light. You can find all that here at etrailer.com.Now that we've gone over some of the features, I'll show you how to get it installed. Typically, when mounting these on a side by side like this, normally you'd want it in the front kind of up here above the windshield because it's going to stay protected up there. The problem is we can't, there's nowhere to attach it here. And if we loosen the lid or loosen the top and pull it up to put it in there, then we can't tighten the top back down. So we're going to have to put it up here. It's not ideal, but we have to do it up here because our customer wants it up top. So what we're going to do is, I went ahead and installed the legs and I installed them upside down. Just an Allen head bolt, five millimeter Allen wrench. It allows you to adjust them. It's got little teeth on it, so you can turn your light. Your kit's going to come with longer Allen bolts and shorter ones. The shorter ones are going to go in here.What we have to do is we're going to have to drill through this inside framing to mount our light on the top. We're going to have to use a longer bolt than what comes in the kit to come down through, so we can put a nut on the bottom. So I mounted this my feet upside down. I set it in like this. Then I took a marker, then I just marked the bottom there. Then what I'm going to do rather than drilling from the top down, I'm going to drill from the bottom straight up, so I can make sure that it goes straight.I'm going to start with a small bit, just a little one and drill a pilot hole. And I'm going just a little bit larger than the bolt that I'm using. Whatever bolt you use, you just want to make sure that it's going to fit through the hole in the foot.You can see I have one foot mounted. How I did it was, I actually used a longer bolt. This is a three inch bolt, quarter inch, half inch head. And then I'm using a nut, a flat washer, and then a lock nut. So if you see what I did right here. You'll notice the roof is really soft. What I didn't want to do is I don't want to when I tighten it, I don't want to pull the roof down. So what I did is I put a flat washer and a nut to give me that bracing when I ran my bolt through. Then I put my lock nut on the bottom.Now because we're using a different bolt, you'll notice you can't get anything on this. You can't get a socket or anything. Ideally it'd be good to use a Allen head bolt. But what I'm going to do is I'll use this. You can take a screwdriver. You can stick it right in there like that and then you can tighten it down. So now let's go ahead and put the other side on and I'll show you how I did it.Go ahead and slide your bolt through. You're going to get a rubber foot pad, slide that on like that. We're going to go just through the hole. We don't want to go through the bar yet. And to make it easier, if you want to loosen the U bracket here that's holding the roof down there you can. It might make it a little bit easier when putting on the washer and the nut underneath. You can see I slid my washer on. Once I get the nut started, turn it down like that. I'll take a half inch socket and I'll run the bolt down as far as I can get it on the top. Make sure that your foot pad is turned the correct way. Put a lock nut on the bottom. Screwdriver on top. Then tighten it all up, just like that.Now we'll set our light in place. Small Allen head bolt, we're going to put a small lock washer on it and a small flat washer that comes in your kit. It's going to go right in the end. Then to put the foot onto the light. Again, we'll take a five millimeter Allen wrench get that tightened into place. And we're going to do the same thing on this side.Next thing we need to do is we need to route our wires and hook up our positive, negative and then to our switch. There's different ways that we can do this. I can drill a hole right back here behind the foot. Put some silicone in it. I can run it straight across like this and not drill a hole in there. It's going to be outside. Run it right down this bar into the engine compartment. If I run it inside, I can attach it to the bar inside and run it down the inside here. Gives it a little bit cleaner look. It's all matter of whether you want to put an extra hole on top or not. If you run it through here, most of the wire's going to be hidden because it's going to be inside.So I'm going to go straight down from the wire right about here. I'm going to drill a small hole just big enough to get this through. Might have to open it up a little bit more. Through like that. You're going to have a wiring harness that looks like this. It's got your relay. These two are going to hook to the negative and positive side of the battery. You have your on and off switch for inside. Then you have a red and black wire that's going to hook to the red and black wire coming off the light. We need to route this underneath the body and through to the inside somewhere. So I think what I'm going to do is I'm going to take a Phillips screwdriver. I'm going to start removing some of the panels here on the driver's side. So that I can get my switch and these two over there by the steering wheel somewhere.We can just add male spade connectors like this. Then we can plug directly into it. We can tape it up to seal if off. And then if for some reason the light ever gets damaged, all you have to do is unplug it, put a new light on and plug them right back in. Everything else is already ran and in place. I'm going to put the connectors on there. These do not come with your kit. But you can find them here at etrailer.com. Then red to red, black to black.Now that I've made my connection, I'm going to go ahead and hook everything up to the battery. Before I tape this up, I'm going to test everything out, make sure everything's working correctly. I'll take some electrical tape, as long as everything's working. I'll make sure I cover this really well, keep any moisture off of it.So how I ran my wires. I removed my hood. Right underneath this panel, it comes right to the front wheel here. I took my wiring harness, set it in, ran my button. My wires connect to my lights. Right here right underneath the back panel here, this side panel on the inside by the door has three Phillips head bolts. I removed those to give me enough room. I went right up behind this bar. This is where my wire is going up to my light. And then for my on and off switch with my panel out, I just fed it behind. It has some sticky stuff on it. I'm actually going to stick it right just like that.My wire going up to the light, these brackets right here that are holding on the windshield. I just went right inside of the bracket all the way up to the top to my wires coming off my light. And we can clean this up a little bit more later on, but we've got it in place. Let's go ahead and hook everything up to the battery.This is my plug for my switch. It is under the engine compartment, but I'm going to go ahead and cover it with some electrical tape anyway. Try and keep any moisture off it, or as much moisture off it as possible. I routed my wires back behind the panel. I just pushed them up in there. Zip tied them here. Ran them right down like this, bundled up, zip tied here, ran across, mounted my relay. Ran my positive and negative wires that are going to my battery straight down here. And then hooked my positive and negative up to the battery post.Now we'll test out our light, make sure everything's working correctly. See our lights working. Now we can go ahead and clean up the rest of our install. I'm going to take some RTV silicone and right the hole that I drilled to run my wires down through. I'm going to put a little bit around that wiring just to keep any water from going through there as mush as possible. It's pretty tight in there now, but just in case. Again I'm Shane, I hope this video has helped you whether you're still deciding or installing the MaxxTow offroad LED light bar for your 2016 Kawasaki Teryx 4 800 side by side.


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