Third Headlight - Suzuki ATV Forum
Suzuki KingQuad 300 Discussions for the King Quad 300

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 13 Old 03-09-2019, 11:10 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
Third Headlight

So there you are, cruising down a trail you just found at night and you come to sharp corner! You can't see what's around there until you arrive due to the fixed fairing mounted headlights, which could be interesting if there is say a creek bank, fallen tree or perhaps even a platypus! That leaves a couple options,

A. Test the structural integrity of the front rack/brush guard on any unforeseen obstacles.
B. Let "that guy" who always tags along go first and he can careen into the unknown precipice.
C. Jerry rig a third headlight that mounts to the handlebars and will cast light around the turn before you get there!!!

Speaking from experience, I chose to employ the third option

I started by picking up an el-cheapo 9" LED light bar from Wally World, it came with angle brackets and locking stainless hardware (+1 for the Chinese company that invested $.79 into the whole thing that I dropped $30 on). Next up is how to mount it? I played around with a few different ideas from billet tubing clamps to zip-ties and duct tape and I settled on welding up a bracket to the OEM crossbar over the speedometer.

I had some slotted angle brackets laying around from another project and it turned out to be the perfect size! I milled up a two new slots to fit the included M8x1.25 hardware, then I cut some steel tubing I had to make a couple gusset braces to help the factory cross bar support the weight of the LED housing.

I've always heard a good welder doesn't need a grinder... well I guess that clears one thing up!
Attached Images
File Type: jpg IMG_9790.JPG (2.28 MB, 11 views)
File Type: jpg IMG_9791.JPG (2.19 MB, 10 views)
File Type: jpg IMG_9792.JPG (2.43 MB, 10 views)
OldReliable is offline  
Advertisement
 
post #2 of 13 Old 03-09-2019, 11:16 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
Making it look less janky

After cleaning the handlebars up, sanding and degreasing I laid 3 coats of black epoxy paint to try to get close to the factory powder coated finish. Wait two days and its cured!
Attached Images
File Type: jpg IMG_9794.JPG (5.09 MB, 8 views)
File Type: jpg IMG_9795.JPG (5.16 MB, 9 views)
File Type: jpg IMG_9796.JPG (4.95 MB, 10 views)
OldReliable is offline  
post #3 of 13 Old 03-09-2019, 11:26 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
Trying not to drop it or gouge it up

Next is installation! Speedo and bar clamps have to come off, not too difficult. I chose to mount the light low to keep vertical clearance as close to stock as possible it made for a snug fit on the speedo cover, looks less tacky that way I think.
Attached Images
File Type: jpg IMG_9807.JPG (4.39 MB, 19 views)
File Type: jpg IMG_9808.JPG (1.37 MB, 17 views)
File Type: jpg IMG_9810.JPG (1.96 MB, 16 views)
OldReliable is offline  
Advertisement
 
post #4 of 13 Old 03-09-2019, 11:34 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
Next step is wiring, after all no electrons equals no light!! The harness included with the light was decent, it had a weathertight quick disconnect included. I simply chopped the harness in half on the light side and added a pigtail on the positive wire. That was then spliced into a handlebar mounted light switch I had laying around. The switch was original equipment on one of my Japanese hare scramble bikes, matches the manual cooling fan switch I'll be installing on the other side of the handlebar pretty well! Plus the light switch is labeled and water resistant as well.
Attached Images
File Type: jpg IMG_9816_1552156193068.JPG (1.88 MB, 14 views)
OldReliable is offline  
post #5 of 13 Old 03-09-2019, 11:39 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
Let there be light!

I wired the light directly to the battery so that I can use the light with the ignition switch and engine off.

It'll be nice for setting up camp after dark without having to idle the engine for 15 minutes to keep the battery from discharging.

Light is bright, works good so far. If the rain ever let's up I'll test it out!
Attached Images
File Type: jpg IMG_9815_1552156502797.JPG (2.21 MB, 19 views)
File Type: jpg IMG_9817_1552156517630.JPG (2.31 MB, 15 views)
File Type: jpg IMG_9818_1552156537575.JPG (1.80 MB, 16 views)
File Type: jpg IMG_9819_1552156555330.JPG (1.79 MB, 16 views)
File Type: jpg IMG_9820_1552156574908.JPG (2.53 MB, 17 views)
OldReliable is offline  
post #6 of 13 Old 03-09-2019, 11:45 AM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
What's that wart on my plastics?!?

While is was in the mess and had my quad apart I went ahead and bored out a 1.125" hole in my plastics and installed a weather resistant 12v power outlet. It will be nice for inflating my camping air mattress and maybe even recharging R/C airplane batteries at the flying field. I guess I could charge my telecommunicator with it too but that's kind of why I like to ride off road so much, to get away from it all.

Anyway it has a 10 amp fuse for safety and works like a champ!

I'll be working on more, utilitarian mods in the future so I'll update you guys as I go. I love these KQ300's!!
Attached Images
File Type: jpg IMG_9813_1552156994151.JPG (823.7 KB, 8 views)
File Type: jpg IMG_9812_1552157040516.JPG (858.3 KB, 9 views)
OldReliable is offline  
post #7 of 13 Old 03-13-2019, 04:40 PM
Suzuki ATVer
 
Masonhorse2002's Avatar
 
Join Date: Sep 2018
Posts: 20
Looks good! Nice build!
Masonhorse2002 is offline  
post #8 of 13 Old 03-13-2019, 06:28 PM
ATV Enthusiast
 
toostroked's Avatar
 
Join Date: Jul 2017
Location: In the Ozarks
Posts: 59
You will like a handlebar mounted light. I did this a few years ago. Actually, I got the idea from a friends Honda. It has a factory light on the handlebars. Mine comes on with the high beam switch, and I wired my low beams to stay on.
Attached Images
File Type: jpg LEDlight.jpg (2.79 MB, 15 views)

1999 King Quad 300

Last edited by toostroked; 03-13-2019 at 06:46 PM.
toostroked is offline  
post #9 of 13 Old 03-14-2019, 08:25 PM Thread Starter
ATV Enthusiast
 
OldReliable's Avatar
 
Join Date: Feb 2019
Location: Central NC
Posts: 71
Garage
I had the oppurtunity to ride the bike last night. The LED is awesome, doesn't cast light all that much further out than the stock lights but man does it fill in the area close in with intense light! I could easily get by with the LED alone. Some like replacing the incandescent or halogens that the bike came with in favor of all LED set ups. I prefer to leave the OEM lighting in place as it helps ease the work that the voltage regulator has to do. Very pleased with the function and form on this mod.
OldReliable is offline  
post #10 of 13 Old 03-14-2019, 08:40 PM
Suzuki ATV Master!
 
TCIII's Avatar
 
Join Date: Nov 2013
Location: texas
Posts: 1,686
I like......good job and idea

2002 King Quad 300
2001 King Quad 300
1997 King Quad 300
2012 POLARIS 500 RANGER
2011 YAMAHA 550 GRIZZLY
2008 Kawasaki 250 Bayou 2x4
2013 TaoTao 110
2014 TaoTao 125
TCIII is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Suzuki ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Putting a 2019 headlight on 2018 model essquad Visual/Body Modifications 1 09-16-2019 02:31 AM
Retro fitting headlight pod, doable??? SslagleZ28 Suzuki KingQuad 2 03-22-2017 04:37 AM
headlight question A3606, HM202, and H6M herbertv2 ATV General Discussion 0 03-08-2017 04:24 PM
Third headlight mod? 50v8 Performance Modifications 2 04-02-2016 11:41 AM
I want a third headlight on my KQ 500 salebrity Visual/Body Modifications 4 02-22-2016 02:57 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome