How do I install a functional brake light on an ATC

[Pinscher62]

Hi all,
Okay, here is Arizona, it is a requirement to have OHV tags. One of the other requirements is a working brake light. This is in addition to running lights between the hours of dusk to dawn. Well, as many of you are aware, my 1986 250SX did not come with brake lights, only running lights.
Does anyone have any ideas how I can install a working brake light on the bike without a huge deal and expense? Is there a kit out there to do this?
Thanks in advance.

[Jason Hall]

You could buy a TRX450 brake light switch and fabricate a mounting bracket. If you drilled a hole, or weld a small bracket to the back side of the brake pedal It would operate the switch. Pretty sure the 450r uses a small spring as linkage between the pedal and switch that pulls the switch to complete the circuit to turn the light on. You would also need to run power to the switch.

[Pinscher62]

Yes, the power would be the easy part. I guess what I am really looking for is the best switch for the job that would not require too much retrofitting. Thanks for the TRX450 idea. I will keep that in mind. I wonder if there is some kind of switch kit that includes a bracket. If not, does anyone have any pics of what they did?
Thanks

[Vealmonkey]

Here's what I did for my 350x. You need a trx450r rear led light, it has running and brake llight leds built in. Make it work on your bracket, as it was pretty much a bolt on for the 350x bracket with no redrilling and the addition of some rubber washers. Then you need to either get on ebay or go down to your local street bike shop and get you 2 10mm banjo bolts that are wired to work with brake fluid pressure. Then install your 2 banjo bolts in place of the stock banjo bolts. Then you need to wire your 2 banjo bolt switches together and run them to the trx45r rear light. Make sure to get the trx450r wire connector as well. The trx450r light will have the 3 wires that should be the same color as the wires for your existing brake light wires, just connect them together. The other 2 wires will be for the brake light switch wires, acutally one hot wire from your banjo bolt switches and the other should be a ground. And there you have 2 independent brake light switch wires on high visibility led tailight that is even honda factory. Then you just need to hook up both brake light switches to hot wires coming in that are only on when the trike is running. Being led, they take up very little power, so shouldn't be a strain on your stock charging system. Hope this helps.

[Vealmonkey]

I think we were all typing at the same time. LOL Here is the trx450r brakelight on my
350x bracket.

[Pinscher62]

Great light idea! I will look into that. Just one problem. My brakes are cable, not hydraulic so I still need a switch idea.

[Pinscher62]

What year is that brake light? That looks great.

[pantera1975]

I have looked at the new yami ratpor and they use clicking micro switches go to the dealer and check it out I put pressure switches in my 86 R for my brakes I got them from RMATV and got a 3157 style bulb base from napa and retroed it in the stock tail lite housing.

[Vealmonkey]

You can go to the local harley shop and find you a couple of the 1970 and earlier sportster universal brakelight switches. They are used with brake rods in the rear so you should be able to make them work with your brakes front and rear. The switch remains stationary and the other part was bolted around the brake rod and when the brake rod moved, it pulled the switch and it lit up the brake light. Hopefully that helps better. I don't mess with the utility trikes much if any and didn't remember that they weren't hydraulic. Sorry. I also believe that any year trx450r taillight is led and all the same. You can pick up a nice used tailllight for less than $50 if you shop around. But make sure and get the harness connecter as well and you will have a nice slick setup. It's amazing how much smaller of a gauge the new honda wires are as compared to a 350x, pretty crazy.

[tri again]

Never made it work but..actually never hooked it up.

I have a hand brake lever that has a wire coming out of it on my xl.

Didn't think much about it until now.

It's prob a brake light switch.

Siiimple.


Just make sure the inspector is watching you step on the brake as you slyly squeeze the handle.

..justt kidding...be SAFE..do it right

[Pinscher62]

Thanks for the advice, I will look into that sportster switch. I will try to post some pics when I get it installed.

[rdlsz24]

The Z400/KFX400 has a brake light also. It's probably pretty similiar to the TRX450R

Rob

[Vealmonkey]

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Here is the swtich I was talking about. There are others, but you usually have to drill a hole or have some kind of bracket. Hope this gives you some ideas. Best of luck and let us know what you end up doing and how it turns out.

[Pinscher62]

Okay, here is what I did. I called the Harley shop by my house and they said they could get a universal mechanical brake light switch but they would have to order it. So I tried another local Harley shop called Ramjet Racing here in Phoenix and he said he had three different switches available. I got a Universal switch made by Custom Chrome Part #12287 for $5.99. This switch has a spring on it so when it is pulled, it closes the switch. It took me a while to figure out where I could install it but I ended up attaching the switch to a cable bracket at the top of the swing arm and the spring to the right brake pedal so when I depress the brake pedal, it closes the switch. I also went to Checker Auto and got a light bulb socket for an 1157 bulb and installed it in the back of my original light. I had to dremel out the hole a little bigger so the socket would fit my light. It fit great and only cost 2.99. Total cost for this project, $8.98 plus tax. I figured I would try a cheap method first before I invest in a $50 light off a TRX450R. I may still get the 450R light but first l will see how the standard 1157 bulb does. I tied the hot wire in on the black wire leaving the ignition switch so the brake light will only function with the ignition on. I am not quite done with the install but so far it seems to be working well. My switch mount is a little cheesy but it seems to be working good. Pics coming soon.
Okay, here is my only concern. The original running light bulb draws .5 amps. The 1157 bulb draws .65 amps on the running light which is not a problem but the brake light draws 2.25 amps. I am just hoping this will not overload my charging system. I figure I can always go to the LED light later if any problems occur. What is everyones opionion on this? Is 2.25 additional amps too much on the stock system?

[Pinscher62]

Okay here are some pics. Let me know what you think.