SUPERATV TSK-CF-ZF95 Deluxe Self Canceling Turn Signal Kit Instruction Manual
- June 17, 2024
- SUPERATV
Table of Contents
SUPERATV TSK-CF-ZF95 Deluxe Self Canceling Turn Signal Kit
What is in the Box?
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Harnesses & Pigtail
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ECU Box
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Install Kit
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Horn & Signal Switches
What You’ll Be Doing
- Remove the Hood, Seats, Console and Dash Panels.
- Routing Front Half of Harness to the Front.
- Connecting the New Horn Connector.
- Removing Front Body Panels
- Modifying a Signal Connector With a New Harness Wire.
- Mounting the ECU Box and Connecting.
- Installing new Switches (Horn and Signal)
- Splicing 2 wires to your Column Connector.
- Routing The Harness To The Back.
- Removing the Rear Body Panels and Rear Decking.
- Removing Rear Rack and Frame.
- Connecting the Factory Light and Other Connectors to Your New Harness.
Installing The Front Half of Your Machine
- First, remove the hood for access. Then remove the Seats and Center Console by removing the screws and shift knob. See Fig.1-3.
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Then remove the dash panel for access to get behind the dash area. See Fig.4.
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Now get your Wiring Harness and start from the center of it starting at the console area as shown in Fig.5. All the wires will go up front except for the end with only 4 connectors which will be fed to the back.
Fig.5 shows the harness being fed thru the console up into the dash panel area to be routed to various locations.
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Fig.6 shows unplugging your Factory Horn Cable in the dash, and plugging in the horn cable form the New Harness in your kit. This will disengage the factory switch and engage the new Horn Switch included in your kit. See Fig.6.
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. Now run the Green/Black wire set and the Yellow/Black wire set up thru the firewall and into the Hood compartment area as shown in Fig.7. The Green set goes to the Passenger’s side signal lights, and the Yellow set goes to the Driver’s side signal lights. See Fig.7.
More detail of each light hookup in the following steps
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Next, you will need to remove some more panels. First remove the top screws from the corner bumper , See Fig.8 , and then the screws underneath, as well as the push-pins from the well cover and remove the panels. See Fig.9.
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And remove the push-Pins and panel from the door area as shown in Fig.10.
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Next, remove the bolt from up under the fender as shown in Fig.10b, and then remove the screws from the upper side panels to release fender. See Fig.11-12.
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Then pull the fender out a little and remove the screws to separate the panels and remove the two bolts as shown in Fig.13. Then separate the fender away as shown in Fig.14-15.
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Once you have them loose and able to separate, pull them apart and place a hammer or something to keep the opening fixed open. You will need this for space to work in the following steps. See Fig.15-16.
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Once you find the connector, notice the Yellow Plug in it. You will need to remove the plug as you will be inserting the separate “Yellow” wire from your new Harness into this spot, then reconnecting the connector. See Fig.18.
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Locate the Yellow wire from your new Harness and insert it in from the same side as the little plug you took out making sure that the metal pin on the end of the wire snaps in place within the connector as shown in Fig.19, and then shown connected together shown in Fig.19b.
Then repeat this same procedure for the Passenger’s side except you will be using the Green Wire from your New Harness instead of the Yellow as you did on this side.
NOTE: This kit utilizes the Factory Signal lights already on your machine. No separate lights to install. These single wires installed into the connectors activate the signals via your new kit.
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Now locate the two larger connectors from your new Harness that are routing to the front, and pull them out to the hood area. Mount your ECU Box in this general location and plug in the two large connectors into the ECU as shown in Fig.20.
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Next you will need to cut or knock out two holes for the Horn and Turn Signal switches. We chose the two center locations for our example. Cut those out and then pull the switch connectors through the holes.
Notice the position of the switches. The Horn is on the Left and the Turn Signal on the Right.
Connect the connectors to the switches and press them back into the holes as shown in Fig.21-21b.
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Now you need to locate the Factory Column Harness inside the dash in the general location shown in Fig.22. You will be splicing a couple wires to adapt to the New Signal Kit.
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Fig.23 shows a closer view of the connector you need to locate for the next step.
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Next, you will need to identify the Orange and Light Blue Wires. Pull them out from the cluster and cut both Orange and Light Blues Wires. Now notice in your kit you will have an extra small cable harness consisting of the Yellow and Green wires. You will splice these to the Orange and Light Blue wires going to your steering wheel column to your dash cluster so it will work and read correctly. The other end of the extra harness will connect to your New Main Harness. Details in the next step.
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Fig.24 shows cutting, twisting off the connector side of the wires (as you will not use these) and splicing the Yellow wire from the new pigtail to the Orange wire going to the column, and splicing the Green wire from the new pigtail to the Light Blue wire going to the column.
New Pigtail Has Only Yellow & Green Wires With Connectors On The Ends As Shown below. -
Fig.25 shows connecting the other end of the New Pigtail to your New Harness. Notice the Spliced end goes to the Column and the connector side of the New Pigtail connects to your New Main Harness.
Before moving to the back section of your machine, be sure to zip-tie all harness cables securely to avoid catching or rubbing or exposed to extreme heat.|
Routing The Harness To The Back Half of Your Machine
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The first thing you need to do is get the harness back to the rear of the machine in order to hook up what is needed. To do this, you will route the back half of your New Harness through the console following your Factory Harness, and routing towards the Passenger’s Side by the E-Brake or easiest way to exit out the back getting the harness into the engine compartment on the other side.
Fig.26-27 show this basic routing path from inside the cab area.
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Once you have the Harness feeding into the engine compartment, and before you can pull it thru into a proper location, you will need to remove some body panels around the engine to have access to the engine and the areas you’ll need to route the harness to. We will do this next.
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The first thing is to remove the upper panel and surrounding plastic. These are attached via Push-Pins or Bolts. Some of these are shown in Fig.28. You will remove the panels and the Lid in the center and set aside. Do this for both Driver’s and Passenger’s sides of the machine.
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Then remove the three bolts holding the air filter on and remove the air filter. This will allow you to remove the cover it is attached to. See Fig.29.
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The next thing is to remove the rack system on the back. Remove all bolts and screws, lift rack off and set aside. See Fig.30. Then remove the support frame that was under the rack and also set aside. See Fig.31.
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Now, remove all the bolts from the Center Section and remove that panel. Then remove bolts and spacers from the main decking cover. Do not loose spacers!
The center section will need to be removed before the main decking can be removed. So take this off first. See Fig.31.
There are a few areas where to locate the bolts to be able to remove the decking. Shown here are just a few. The rest are fairly easy to find. See Fig.32-34.
NOTE: There is a bolt underneath by the muffler that will need to be
removed that is easy to miss. See Fig.33b.
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After all the bolts have been removed, lift decking to gain access to all areas underneath.
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Once the Main Decking is up out of the way, you can now pull the harness on out and start to route the cables to where they go. Fig.35 shows the Harness entering the engine compartment from the other side center and routing towards the Passenger’s Side of the machine.
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After you’ve pulled the harness out the back and into the engine compartment, you can now start connecting the harness to the machine. Fig.36 shows the Factory Harness and Connectors that you will be connecting the new harness to.
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Now disconnect the factory plug on the Driver’s side and connect the connectors from the New Harness as shown in Fig.37-38.
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After connecting the New Harness to the Factory one on the Driver’s side of the vehicle, your finished install on this side should look like the one in Fig.38.
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Then, unplug the Factory Harness connector on the Passenger’s Side and connect the New Harness connectors to the Factory Harness plugs as you did for the Driver’s Side. See Fig.39.
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After both sides have been hooked up, there should be one remaining Red & Black cable that is available for a License Plate light if you choose to use one, or for another electrical application. See Fig.40.
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Once all connectors have been connected, be sure to Zip-Tie harness and all cables up and out of the way of moving parts, possible snagging or excessive heat.
Reverse the process for re-installing the body panels and all other items removed during the removal of them. Go back and review the instructions for removal so you won’t forget which item was taken off first, second etc.
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References
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