Foreman 450S/ES brake light mod - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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post #1 of 13 (permalink) Old 08-05-2013, 04:40 PM Thread Starter
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Foreman 450S/ES brake light mod

OK, I said I would post up a write up on this if someone wanted the info so here it is with parts numbers and pics to follow. This thread will be a work in progress as I get more pics to add to it. This mod shuld also work on other models without the brake lights on them, just check your brake levers and see if they have the holes for attaching the brake switches and you should be good to go.

Here are the parts/w numbers that I used on my mod:

2 each Honda brake switches - 35340-HR0-305
1 Honda Stop switch harness - 32105-HP0-A00
1 Honda stop switch collar - 35345-HF1-830
2 Honda screw-washer - 93893-04022-07
2 replacement trailer light assemblies and pigtails - can be found at any auto part store (NAPA)
15 feet 18 gauge wire (I used green)
1 package of male and female 14-16 gauge bullet disconnects

I first started by taking the seat, the little rt side panel, and the front plastics and rack off the machine. I also removed the little cover that goes over the handlebars so I could wire the brake switch power wire to the keyed on/off switch. I connected the power wire to the winch power wire so it would only operate when the key is on.

Next I installed the brake switches on the brake lever assemblies using the switches and screws I ordered. I had to cut one of the screws down a bit as it was a bit too long. I also cut some of the rubber boot off the left lever so it wouldn't interfer with the brake switch. I may try and get a boot from an 05 Foreman and see if it will work on my machine.

To be continued...........

2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.

Last edited by AkATVHunter; 08-06-2013 at 11:14 AM.
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post #2 of 13 (permalink) Old 08-06-2013, 10:41 AM Thread Starter
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The first pic is of the brake switch and the collar you will need so you can install the switch on the left brake lever. It will mount on top of the lever with the collar mounted underneath it. The collar is slanted so it only fits one way.

The second pic is of the right side brake switch, it mounts underneath the right brake lever and does not need a collar.
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2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.

Last edited by AkATVHunter; 08-06-2013 at 11:15 AM.
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post #3 of 13 (permalink) Old 08-06-2013, 11:05 AM Thread Starter
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Next step is to get the brake switch harness and remove the wiring for the start in gear switch, which does not exist on this machine. I cut the white connector off one end of the harness as it is not needed. The wires for the brake light switch should be brown and green and are the same color for both sides. The wires for the start in gear switch would be the 2 lower wires that feed to the right side and are not the same colors as the brake wires.

The brake switch wires have little rubber boots on them, connect them to the brake switches. Route your wiring accordingly and wire tie it all in place. I used several of the pre-existing wire ties along with some new ones.

If you look at the pic of the IPB, you'll see the harness as item # 4 and can see the wiring for each side and the other end where the white connector is located. I used this harness because it was cheap and made this mod a lot easier to do.
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2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.
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post #4 of 13 (permalink) Old 08-06-2013, 11:13 AM Thread Starter
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Run your power wire down the steering stem to a location where you can easily access it, wire tieing it as you go. Once you find your power wire, connect the power wire from your brake switch harness to it. I soldered it and used heat shrink sleeves to cover it but you can do it which ever way is best for you. Once this is done, it's time to start running your brake light wire to the back of the machine. You'll need to get the wiring you bought and solder it or connect it with bullet connectors to the loose brake wire switch (I used the green one).

I ran the wire along the frame with the pre-existing wire bundles and wire tied it to make it look factory. You'll want to run it all the way to the rear tail light on the right side and leave enough so you can tie it all back with the existing wires.

2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.
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post #5 of 13 (permalink) Old 08-06-2013, 11:37 AM Thread Starter
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Once you have your wire all routed it's time to get it connected to the pigtails. Disconnect the 2 wires from the back of the light assembly and pop it out of the grommets that hold it in place.

Get your trailer light harness pigtail (1st pic) and cut the terminal off the white wire. Install male bullet connectors on the white and black pigtail harness wires (2nd pic). Connect the white wire from the pigtail harness to the factory green wire using the existing bullet connector on the factory wire. Connect the black wire from the pigtail harness to the factory brown wire using the existing bullet connector (female). You should have 1 wire left on the pigtail and the wire you ran from the front of the machine.

Now you'll need to cut the wire you ran but leave it long enough so you can stow it with the rest of the tail light wires. Take the leftover wire and connect it to the brake light wire you ran from the front of the machine. Use a bullet connector (female) as seen in the 3rd pic. Run the leftover wire over to the left side and you'll use this wire as your brake light power wire for the left side.

Now you'll need to disconnect all the wires going from the pigtail to the quad wires. You need to do this because you will need to run the wires through the grommet on the white plastic housing that holds your tail lights in place.
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2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.

Last edited by AkATVHunter; 08-06-2013 at 11:53 AM.
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post #6 of 13 (permalink) Old 08-06-2013, 11:50 AM Thread Starter
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Remove the white plastic tail light housing from the rear fender by removing the 4 screws. Get your new tail lights (1st pic) and check for fitment. I had to enlarge the big hole on the white housing so my new tail lights would fit and I used a dremel to do this. Once you've got the new tail lights where they fit on the housing (2nd pic), run your pigtail harness wiring through the existing grommet (as seen in pic # 2) and connect it back to the existing tail light wires and your new brake light wire. Connect the pigtail connector to the new tail/brake light.

Install the new lights on to the housing by drilling 2 small holes and attach the lights using small short sheet metal screws. Apply some rtv before attaching the lights to the housing to keep your new lights waterproof.

Now you should be able to mount the whole thing back into place using the 4 screws for each side. I also used the rubber seal from the old tail lights to the new lights to make it look factory.
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2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.
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post #7 of 13 (permalink) Old 08-06-2013, 12:03 PM Thread Starter
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We're just about done. Once you have everything back together and wires tied out of the way it's time to do a functional check.

Turn your key on and turn on your lights. Your tail lights should come on like the 1st pic.

Now hit your brakes and you should have brake lights like in the 2nd pic.

That's it, if everything is working as advertised you can put everything back together. I double checked all the wiring to make sure everything was stowed nice and neat before I put it all back together.
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2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.
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post #8 of 13 (permalink) Old 08-06-2013, 01:19 PM
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Good job, thanks!

2003 rancher es 4x4
2013 foreman 4x4
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post #9 of 13 (permalink) Old 08-07-2013, 08:37 PM
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nice setup,but a lot of work compared to the banjo bolt an the banjo bolt is waterproof but i like the lights in the plastic where did ya get them an how much? are they waterproof too?

01 foreman on 29.5 laws,full snorks,axle paddle,kimpex rear cargo seat,2 in lift,front bumper guard,disc brakes,hockey puck spring spacers. new bike is 04 rincon 650,full hmf exhaust with snork,disc brake conversion,29.5 outlaw 2s on 14 in diesels,28%gr,final shift mod,2 in hl lift kit,triangle atv snorkle kit,dyna adjustible ignition,full metal jacket underbody,to come are tool tubes,winch an custom built front bumper
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post #10 of 13 (permalink) Old 08-19-2013, 10:59 AM Thread Starter
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The lights I used are just regular trailer lights like they use on flatbed trailers for hauling quads/utv's/sleds etc, etc. It's really not that much work, it took me longer to take the plastics and rack off than it did for me to do the mod. You can also go with the led lights, they are a bit more money comapred to the regular lights though. These lights are waterproof and are also very bright. 3 rides so far and the brake lights are working like a charm.

2004 Foreman ES
A bunch of goodies on it.

2009 Honda RancherAT 420 with EPS, IRS, disc brakes, and Traxlox. Mudlites, Kolpin cargo box, Moose hot grips, AP boot guards, Warn 2.5Ci winch, sra gear reduction.
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