Hello, John Talley here with Partzilla.com.
Today I'm going to show you how to install an accessory fuse kit on our 2018 Kawasaki
Pro FXT.
Really not that tough to do, just need to get this grill out of the way, that way we
can use that corrugated tube that's actually going to feed the wires back to our battery.
So, let me go grab a couple of tools and we'll dive into it.
Alright guys, this is going to be a skill level two, but it's nothing to be afraid of.
Let's go over some of the tools that you're going to need to pull this off.
Just a flat blade and a Phillips screwdriver.
On the wrench side, an 8, 10, 12, and 13mm.
On the socket side, just need an 8, 10, 12, and a 14mm.
On the Allen side you need to have one of these little 3mm, that's going to be important.
AS usual, you're going to need a good set of needlenose pliers, 3/8ths and a quarter
inch ratchet, a couple of different extensions, and a razor knife.
Beyond that, might want to invest in one of these.
This is actually the tools that you use to remove those plastic rivets which are used
everywhere on the modern machines.
Beyond that, you're going to need just regular drill.
The two bits that you'll need to have in your kit are a half inch and a 15/64ths.
Alright, as far as the parts go, there's one number that you need to get, and that's right
here.
Put that in your search bar and it'll take you right to it.
So, once you've got your tools and your parts together, I can go over there and show you
how to do it.
So let's go.
Basically you have three Phillips screws on either side.
There's one here, one hidden in here, and then one down low, right here.
So we're going to start pulling those off and then we pull the grill forward, we'll
disconnect the lights and just take it all the way off the vehicle.
Now we need to just concentrate on these little plastic rivets.
If you don't already have one of these, I recommend that you invest in one.
Otherwise you're gonna maul them trying to use just a regular pair of needlenose or something
like that.
So, do yourself a favor.
Pick up a set of these.
Alright, like I said there's seven on either side.
So you're basically one, two, thee, four, five, six, and then number seven down here.
Same thing on this side.
Alright, at the back of the light, there's a green plug and it's got a little red tab
right here.
Push that red tab back and then the plug will pull off.
Now, just lift this out.
We'll set it to the side.
Get this cover out.
Alright guys, what we need to do is just access the battery and basically it's just removing
this one cover.
Just a clip down at the bottom-- or latch rather-- pull it.
Then there's one around the front that's actually a clasp.
And you lift up, and then down and out.
This tube that you see-- corrugated tube actually runs all the way to the front and that's what
we're going to run the main power wire through.
This is as far as we have to open up the vehicle, so what we need to do now is head over to
the teardown bench and start putting together the actual fuse panel.
First, want to grab a little bit longer than the other three, it's a 10mm head bolt and
it's 20mm long.
You want to put it through this ground, through the plate, through this ground.
And then on this side just a split washer, and a regular 10mm bolt.
When you're done it's going to look like this.
You'll notice that they've got this little edge protector, it's actually going to end
up right here.
Alright, let's go ahead and get our relay mounted up.
All you're going to need is just two more of these 10mm head bolts and these two locking
nuts.
Alright, let's head back over to the machine and get this mounted.
Alright, let's go ahead and take the negative off the battery.
See the bracket's gonna go here, this long bolt's going to go up through it, and then
there's a hole right here where we actually bolt it to the front section of the unit.
So we've got our last bolt here, gonna get on a washer on the inside.
We've got a locking nut that's gonna go on the other side.
Alright, now the fun part.
What I'm doing now is crawling under here to get this bolt on the back side.
Alright guys, it's going to be hard for you to see this, but what I have to do is remove
the plugs on the corrugated tube back here and up under the hood.
So I'm just going to use a flat blade screwdriver.
Hopefully, that will be enough to get up under the edge and push it out.
Now, just need to go up front and remove that plug as well.
There it is.
Basically this is the wires that have to go through that little corrugated tube.
What I'm doing is just folding back this one, the smaller one, so hopefully that doesn't
get caught on anything.
Just going to try to feed it straight through and see how she does.
We can untape this.
Let's remove that so I've got a little more area to work with now.
Alright, we're going to take this section or corrugated tubing and just add it to the
cabling that's actually exposed right now to protect it.
Feed this part of the tubing actually down inside of the part that 's attached to the
vehicle.
Now I'm just going to cut off the excess and then tape off the top.
Alright, now we're gonna tape off where those two pieces of corrugated tubing come together.
And if you don't have any electrical tape you could have used a couple of the zip ties
that actually came with the kit.
I prefer the look of putting the tape on there.
Alright, let's start making our connections.
With the cable that we just ran, they're calling the main cable.
Don't forget to put this back on.
That goes to the right side of your relay.
Alright off that main harness, this brown wire goes here.
That six inch ground is attached to your plate.
It goes over here.
This cable goes right here.
Make it all pretty like the picture.
Alright next, let's go ahead and get the fuse block mounted up front.
Want to position it about right here, pretty much as far in as you can because we don't
want it to interfere with the radiator, which runs right next to it.
Now what I'm going to do is use a punch tool to mark the points to drill.
There they are.
And we're using a 15/64 drill bit.
Using these bolts, and these lock nuts on the back side.
Alright, next, lets' go ahead and get our negative post mounted.
Once again, stay clear of the radiator.
Alright, let's go ahead and bring over our red wire-- battery wire that is.
We can get it on the post of our fuse block.
Slide the cover over the top.
Next, go ahead and get our ground post tightened down.
Alright guys, what we need to do now is remove the dash and it's just held in by five of
our favorite rivets.
What we're after is a brown wire with a red stripe, and that's where we plug that other
18 gauge into.
But we have to remove this to get to it.
Alright, this is the wire we're after.
It's a brown with a red stripe.
There she goes.
Set that back in place.
Alright, now let's head back up under the front for a second, because we need to get
this grounded.
So we're going to be drilling a hole in the plastic and then routing it through down to
the frame where there's going to be a hole there.
We just need to scrape off where the paint is and then bolt it down to the frame, creating
a ground.
What we need to do is drill a half inch hole about an inch up and then an inch back from
this point.
So it's not an exact science, that just gives us in the general ballpark to bring it through
and get it down to that hole in the frame.
So, right about there.
Start off by just making a smaller hole, and then we'll bring out the half inch bit.
Alright, next, we need to get up under here.
We just want to take off the paint so we can get a good ground.
That simple.
Let's fee our wire down and through.
Alright, Kawasaki doesn't tell you you have to do this, this is just a personal preference
whenever I scrape off the frame, I want to try to protect it from rusting so, some type
of epoxy paint, you can pick it up at AutoZone or wherever.
But, this will keep it from rusting.
Alright, we're going to go back to the battery.
WE need to get our positive connected up.
So what we're going to do is actually run it through this protective cover on the positive
post and we're going to attach it right there.
Get that covered back up.
Now, we can reattach our ground.
Take off the nut on the end and then put our eight-inch brown wire over it.
Remember this tie that was holding on the breather?
Reattach it to the bracket.
Alright guys, as far as the fuse kit is concerned, it's pretty much done.
Only thing we have to do now is just basically put the machine back together.
So, let's get it finished.
Getting our grill wiggled back in.
Now just getting my lights plugged back in.
Don't forget to push that little red section back, because that actually locks it in place.
Start getting our plastic rivets back in.
There's going to be seven per side.
Now let's get our screws in place.
Well alright guys, that pretty much wraps this one up.
Well listen, when are you going to need to install parts like this?
Well basically, if you're gonna add anything to your machine it all starts with the fuse
harness kit.
Because with it, and you have a rear harness kit and a front harness kit and it also ties
into your-- potentially you're using a winch or any type of lighting, windshield wipers,
anything.
You have to start off with a fuse accessory kit.
well, listen, if you need any of the parts for your machine, why don't you come see us
at Partzilla.com and we can get you taken care of and walk you through this potential
minefield of not having the right parts.
If you have any questions about how I did it or any questions about your particular
machine, if you would leave them in the section below and I'll do my best to answer them.
We just want to say thanks for watching and shopping with us at Partzilla.com because
all of that makes all of this possible.
So thank you and we'll see you next time.