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Xrs_800
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907 Posts
Discussion Starter · #1 ·
Since no one really has done this or given any info about where they took power from or set it up, I decided I'm going to go for it. What could go wrong right lol.

I'm starting with a 2012 xrs 800 etec with no electric start or battery. I will be using power from the 12volt plug in that's located under the air box.
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I will be using the wiring harness that came with the 2. 6 inch led light bar from rough country. Or making my own
Using this diagram
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My mount will consist of Mounting the light bar off the riser block
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A buddy of mine is machining me the mount soon. I have already checked and I can still see the gauges with the led light bar there
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Photo of the 2 light bars hooked up to a car battery in a dark garage.

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The light bars I picked up from rough country's scratch and dent on ebay for 40 bucks . What a deal especially when they are regular $120 new. Any questions or concerns or problems you see let me know.

Thanks Woodsy
 

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True happiness is never trying a sled better than
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Yup. A few guys posted how they've done them. You got a great price on those.
 

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Xrs_800
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907 Posts
Discussion Starter · #5 ·
Change of plans on mounting it I'm thinking. The light bar is just too big for the handlebars. My father showed me something for mounting it. I'm thinking of putting it on the dash using trail systems mount for a gps. The light bar weights 2 or 3 pounds so the mount should hold it.
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The mount is $93 which is crazy. We have one for a xs and it works great. So I'll be probably ordering the part this week. I'm planning on wiring the light bar up this coming weekend if I have time. Any other ideas for mounting ik all ears

Thanks woodsy
 

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2,329 Posts
Here's how I mounted my 6" single row bar. Black oak 30w led. Axial alloys bar mounts.

I also used the relay method. You shouldn't have any issues with a light bar this small, but it's not good practice to run all power through the switch.

DB6EA38A-0F4A-4189-96F4-4EEC71A03217_zps

011AD032-EB5F-45A5-B1AB-4A3E6C9A93E0_zps
 

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So even with the LED light bar mounted on top of the handlebars the flood light pattern still lights up the gauge pod area more than I'd like. I'm running a 6 inch riser and the bar mounts hold the LED light bar another 2 to 3 inches above the handlebars. I'm running a light bar that has a split pattern between spot and flood. As you can see I am also running the smallest windshield you can on an XP, and it's still catching some of the flood light from the LED.

I'm going to raise the LED light bar up a little bit higher and angle it more forward, to try and cast more of the light over the top of the windshield.

Otherwise, the set up works great! I like that the light turns with the handlebars. About 3300 lumens out of this little 30w light bar. That's more than the (2) 65w high beam bulbs combined.
 

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Xrs_800
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907 Posts
Discussion Starter · #8 ·
Looks good npickle12. Definitely liked the idea of up high but seeing the gauges is useful for me. I'm ordering the mount today while it's on sale. So hopefully have all the pieces here next week. I also picked up a switch and a rubber boot for the switch.
 

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Xrs_800
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907 Posts
Discussion Starter · #9 ·
Finally wired the light bar up. Everything is done besides adding the switch.

Here's how it was done
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Soldered into the 12volt power supply under the hood. I used rough country's harness which had a in line fuse and a relay so it was pretty simple. I ran the switch up to the dash and stored all extra length wiring behind the gauges
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Plenty of room up there. I ran the wire for the light bar out next to the steering post and to the light bar across the dash
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I may change the wiring route but it works for now.
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I mounted the light bar using trailsytems gps mount which was very pricy but worth it. I went to the local hardware store and bought round head bolts and ground the heads to t bolts so they would slide in the rail mount on the dash. The mount is pretty stable actually. The light bar also clears the windsheild.
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The switch that I'm using is temporary till I can figure out how to wore the toggle switch up now
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The switch isn't waterproof so if it lasts the week I'll be happy. Any questions let me know. The light bar is a 6inch spot flood combo. I'll post pics of it lit up tomorrow
 

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Xrs_800
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907 Posts
Discussion Starter · #10 ·
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We did get everything finished today and ran the sled around the yard with no problems with the light. Bad part is the stator doesn't give enough power to work at idle so the light turns on at 4000rpms. Isn't a big deal since the clutch engages at 3800. I'll post up pics at night tomorrow.
 

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Xrs_800
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907 Posts
Discussion Starter · #12 ·
Looks nice. I'd like to try it but I have a huge windshield. Thought about the front bumper?
I have and I really did not like the idea due to the light bar has no protection from brush or cornstalks. Also I don't have a mount idea for it
 

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Xrs_800
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907 Posts
I finally got the sled out at night and did a comparison. Stock headlights at 4000 rpms every photo is at so their is no change in variables.

Stock
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Light bar with headlights
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Headlights
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Light bar with headlights
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Thanks for the write up and pics. I do however have one question.....why not just get a set of HID/LED headlight bulbs? I picked up a set of Fluxbeam bulbs for $89, plugged them in, and bam 6000k lumen. It's like staring into the sun..
 

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Xrs_800
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907 Posts
Discussion Starter · #15 ·
Thanks for the write up and pics. I do however have one question.....why not just get a set of HID/LED headlight bulbs? I picked up a set of Fluxbeam bulbs for $89, plugged them in, and bam 6000k lumen. It's like staring into the sun..
I did look at hid and led but they all had to many shadows. With the light bar it covers up the stock lights shadows.
 

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your post (30) should just come off the battery only, you don't want to rob any power from any other location of the sled, and the manual dash switch should be between post 87 and the lightbar.

having two feeds to post 30 is redundant anyway.
 

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Xrs_800
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907 Posts
Discussion Starter · #17 ·
your post (30) should just come off the battery only, you don't want to rob any power from any other location of the sled, and the manual dash switch should be between post 87 and the lightbar.
having two feeds to post 30 is redundant anyway.
Yes I see where you are coming from. I scrapped the drawing and used the harness from the light bar. It was a simply wire up. Only issue is the light bar doesn't turn on till 3800rpms. So very slow riding it is useless. I don't have a battery in my sled so it works for me.
 

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Xrs_800
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907 Posts
oh i see now why it was done that way, it didn't dawn on me till you said no battery. hopefully you have it fused to whatever wire you your drawing from however....
Yes I have a 30 amp fuse that was already built into the harness. Rough country made this very easy to wire up. It has a relay and in line fuse. All you have to do is cut off the battery prongs and wire those into the acc. Plug. Pretty simple. I've been using it for about 500 miles on this set up and its been working great. Freezing cold temps to crazy bumps and no issues
 
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