Does anybody have any pics, or ideas of where the best place to mount a switch panel would be? I would like to install a 3 or 4 switch panel on the 'Cat for running a set of accessory lights in front, a set of back up lights, and a "fan off" switch. The fourth, if installed, would be an "accessory" or optional switch should I happen to think of something else I needed later.

I've got the Auto 'Cat, and was thinking that it should probably be drilled into the black plastic just beneath the ignition assembly, below the lighting display (oil, heat, brights, neutral, reverse, etc.) I don't see it causing any clearance problems here, and don't imagine it would interfere with the ignition either, though it would be a pain getting all the wires in there properly. Any thoughts?

Also, what's the easiest way to install a "fan off" switch? I haven't looked to closely at it yet, though I should probably get after it before elk season starts. It will be pretty nasty up there with lots of thick mud and snow, and tons of water.

Oh, thanks again to Winston and TCat, I found the rear accessory plug buried in the excess winch cable and installed a second cigarette style accessory plug in back just above the frame. My dealer had the adapter piece for $10.70, so I picked it up and put it on.

Thanks again!

Mike

 

Re fan switch.
I installed a circuit breaker in line with the fuse from the fuse box. It is a 5 amp breaker so it kicks out before the fuse blows. The only problem is that to get it to reset you have to turn off the ignition for a couple of minutes. The fuse is marked on the fuse box, I just pulled the stake on off of the fuse box and put my breaker in-line, you could do the same with the switch. Once you have picked a location please let me know how it worked out as I am going to install a switch as well.

Cheers Jim

 

I installed my "fan off" switch just where you were thinking of installing yours. I think it might be tight there to install as many as four. As far as wiring the switch, I spliced into the wire for the fan right below the fuse panel, between the fuse and the fan. That way my fan wiring is all fuse protected. Another thing I did was to use a "lighted" switch. As long as there is power to the fan, the switch is illuminated. At a quick glance at the switch, I can tell if the fan is powered. I'm glad I did it that way because just last week-end I got into some deep water, forgot to turn off the fan and after a short while, noticed the switch wasn't illuminated. Checked the fuse and sure enough, it was blown. Should have remembered to turn the fan off before running in that deep water---(4 times!!!). I carry spare fuses anyway so no problem!!

 

I can't think of anyway to do it and make it look good. You can install about two (three real tight together) rocker switches by drilling holes in the indicator panel, but the ignition still takes up about half the room and all of the room on the right side. I have my reverse light switch mounted on there, and it looks real good. For that many switches, you would have to mount them in some fabricated thing and attach it somewhere, like to the lower part of the handlebars or maybe in front of the speedomter where the two bolts hold it in place. You could fabricate a piece of metal that would rise up and over, but that still would look wierd.

A last ditch effort would be to make some kind of thing that bolted into the plastic indicator thing next to the ignition and came up from there. Then mount a little switch box on it, but I don't think that would be too sturdy.

To tell you the truth, I don't have a clue how or where to do it. Good luck.

 

Thanks for the tips guys, I'll see what I can come up with.

Andy:
That is the thing I was worried about. Having three switches (forward, reverse lights, and fan off switch for deep water) and still looking decent, not like crap. Thing is, the farm store that I work at got in some rocker switch style switch panels that is one single unit, four switches long. It uses two screws to mount it, and houses the four switches, so it looks nice and clean. That's what made me think it would fit under the ignition spot, and still look good. I've seen switches like this come in a dual kit before for KC lights, or PIAA's before, but never in a four switch panel. Not sure what I'd do with the fourth though. Maybe it would be better if I just mounted a dual switch set-up for the lights there, then put the fan off switch somewhere else. Kind of wanted to keep everything in one spot, and looking as "clean" as possible if you know what I mean. I don't care for things that look "rigged", ya know. I've got the back-up lights, just haven't had time to wire everything up all at once, the "right" way yet.

Thanks to all for the thoughts!

Mike

 

I got some automotive driving lights a few months ago and mounted them to hang down underneath the regular headlights. They came with a little LED push button switch that I just mounted to the handlebar with wire ties. Looked real flush. Nice setup. Then I got pissed cause they weren't very bright, and they filled up with mud when I got them underwater so I took them both off. I ended up using one as a backup light with a separate rocker switch that I mounted on the instrument panel to the left of the ignition (sticking straight up, not on the side or anything. Just drilled a hole through it and it all screwed in real flush. I did the same to BigBadCat's 454 using the other light. I still have all the original wiring for the lights on the quad, just not hooked up to any lights. I had planned to get some brighter lights and use the same wiring package (it has a separate fuse box and all), but if I sell it, then that is history. Check out some different types of switches and you may be able to mount one to each side of the bars, and then mount another switch on the panel. Other than that, your imagination is as good as mine.

 

How about making a pannel that bolts between the speedometer and the handle bars. Have it to where there are 2 switches on each side of the speedometer so it looks balanced. IT would also be out of the way and not block any other things. Wiring it might give you alittle trouble-- getting it to look good and all.

 

Thats a good location. It would take a little work to fabricate the mounts, but it would look good, and not be in the way of anything.

 

Mike,
That's where I mounted my fan switch (under the gear indecator lights) and it works great. I mounted the switch on the far right side so I could mount a 2nd switch. Well I got home from work today and that nice man from UPS left me a suprise on my steps. A set of Warn trail lights so the project was on....I had a switch for my backup light that I was putting off installing. I have been just pluging it in to the rear accessory plug when I needed it. so now I thought is a good time to get it all wired. What a job! I mounted the trail lights on the rack just in frount of the brushbuster. I mounted them in the little slots on the rack, had to drill the holes a little bigger no big deal. I could only mount 1 more switch under the indecator lights so I mounted the trail lights switch on the left handel bars as the diagram that came with the lights showed. By the way the instructions that came with the lights said " Just follow the diragram" Thats all I ever do any way, who's got time to read it? I want to ride!!! It took all afternoon and part of the evening. to get every thing wired and zzzzip tied up. It as a tight fit with the fan and backup light switch plus a thick wire from the trail lights wiring harness that was to conect to the ignition wire. Got it all wraped up just at dusk and All the lights worked and so did the fan so my daughter and I took off for a test ride. 2 miles from home and it just dyed, no power at all. OK ,no power at all had to be the 30 amp fuse at the starter relay. Now the one time I take off on the 4 wheeler with out my gear bag thats when I need it, No flash light. my daughter starts walking home to get "little bad" (my sons Y2K auto) and I feel around back there and get the blown fuse out and a new one in, turn the key and blow that one also. OK one more fuse left, so I take all the leads of the battery and just hook up the + and -. Turn the key and blow that one also.. Got a short in the igniton wire some where. So Jennifer, my daughter, towed me home in the dark, with all thoughs lights and switchs just mocking me Well its back to the drawing board tomorow.

sorry for the long story.
scotto
1999 & 2000 500 cats with stuff on them.

 

Scotto:
I hate to say it, but I enjoyed the story! Only because I've been there though, in my '80 Chevy shortbox pickup that I built. Only thing was, I was about 30 miles out, with nothing. I was lucky enough to get the sideband hooked directly to the battery and pull enough power to reach a buddy of mine who managed to make it out to where I was at a few hours later. Took us about half the night to get the truck running again, all because of one bad ground. By the sounds of things, that could very well be what keeps blowing fuses on the mighty WarPony. Let me know what you find after you get it figured out, I'm curious to know now. Also, which Warn trail lights did you get? I've seen a couple different types, in different wattages. That's exactly where I plan on mounting mine as soon as I get them. If you wouldn't mind, could you post a few pics of how they look? Were they bright enough do you think? Course I guess nearly anything will be brighter than the stock lights.

Boner, Andy:
I like that idea as well. I decided to take a welding class while I'm back in school. They supply everything, and we are able to build or design whatever we want, so it is possible that I could come up with something of that nature to mount on the 'Cat. They said we'll be using aluminum and diamond plate mostly, and some of the heavier metals later. I have no welding experience, other than playing around building a tailgate for my trailer, so it should be interesting.

Thanks guys!

Mike