Headlight

• 1). Locate the voltage regulator. Depending on the application of the motor, such as a motorcycle, off-road vehicle or boat, it might be necessary to remove a seat, gas tank or an engine cover to access the regulator. Use standard or metric tools to remove the necessary components.
  
  
• 2). Start the four-stroke engine and allow it to idle. Attach the positive and negative wire clips from a voltage meter to the corresponding electrical tabs on the voltage regulator. Set the meter on “Ohms” and note the resistance at the voltage regulator. Turn off the engine.
  
  
• 3). Enter the resistance quantity into an Ohm’s calculator that you access online or though an electrical supply outlet to establish the wattage of the headlight. Obtain a 12-volt, two-wire headlight with a ground.
  
  
• 4). Mount the headlight to a stable platform, such as a motorcycle steering head, off-road roll bar, boat railing or superstructure. Use U-bolts or metal clamps to mount the light and include rubber insulators between the light and the mount to prevent an electrical short.
  
  
• 5). Attach the ground from the headlight to the mount with a small hose clamp or the provided wire clip.
  
  

Wiring Circuit

• 1). Locate the electrical terminal block. The block might be close to the voltage regulator or mounted below an instrument panel. Route a pair of 14-gauge insulated wires, one black and one white, from the headlight to the terminal block.
  
  
• 2). Cut the wires 12 inches longer than necessary with wiring pliers, to allow for stripping and attaching wire connectors. Secure the intermediate sections of the wires away from the motor with nylon ties.
  
  
• 3). Strip 1/4-inch of insulation from the ends of each wire near the terminal block with the pliers. Fit crimp-on connectors with a metal tab onto the ends of each wire. Protect the connections with electrical tape or heat-shrink tape.
  
  
• 4). Connect the black wire to one of the steel screws on the “Hot” side of the terminal block with a screwdriver. Connect the white wire to the corresponding brass screw at the opposite side of the block.
  
  
• 5). Strip 1/4-inch of insulation from the ends of each 14-gauge wire near the headlight. If the headlight wires are not previously stripped by the manufacturer, strip 1/4-inch of insulation off the ends of the headlight wires. Fit a two-way crimp-on connector onto the ends of each wire. Crimp each connector onto the corresponding black and white wires from the headlight. Protect the connections with electrical tape or heat-shrink tape.