We’ll be installing this kit on an ATV that’s used for plowing snow, but the Tusk Grip Heater Kit can also be installed on motorcycles and snowmobiles with a 12-volt source. The heat panels fit right underneath the handlebar grips and are easy to install. The grip heater kit features a two-way toggle switch that can be mounted just about anywhere on your machine. It’s got both a high and a low setting to keep your hands warm and comfortable in the colder weather. It’s recommended to install a new set of grips when installing these grip heaters, because a lot of times, the grips cannot be reused after being removed from the handlebar. We chose to grab a set of Tusk ATV grips. So the first thing we’re going to do is find a keyed power source we can use to power the heaters. A lot of times a power outlet is a keyed power, so we’ll go ahead and check that with a test light and it looks good. If your machine doesn’t have a power outlet, you’ll have to find a different keyed power to run your grip heaters. Now we’re going to cut both grips off the handlebars.
After that, we need to clean any leftover rubber or residue off the bar end. We’re going to use a razor blade to do that, and then use a little bit of contact cleaner to get it clean. Now that the bars are clean, we’re going to remove the front handlebar cover so we have access to run the wires along the bars. Now we can install the grip heaters. So first we’re going to slightly bend the two wires of each heating element. When you do this, make sure you bend behind the soldering joint, to make sure the joint isn’t weakened at all. After that, go ahead and peel the backing off and wrap it around the handlebar. Make sure you locate the wires so they won’t interfere with any of the handlebar controls or switches. As a precaution, we’re going to stick a layer of electrical tape over the wires so just in case the wires get pulled on a little, it’ll keep the stress off the soldered joint. Now we can install this grip. Apply a little grip glue to the bar end and inside the grip and then slide it onto the bar. Now that this grip is in place, we’re going to install the other heating element. Peel the backing off and stick it to the handlebar. Once it’s in place, go ahead and wrap the wires in electrical tape like we did with the other side.
When installing this on a motorcycle twist throttle, we suggest using a small zip tie to tightly secure the wires to the throttle tube. This will ensure the throttle movement will not break the solder joint. Make sure you leave enough slack in the heater wires for nonrestrictive throttle movement throughout the entire throttle range. So now we can just go ahead and apply a little grip glue onto the bar and inside the grip and then slide it into place. Next we’re going to pick a spot to mount the switch. So just drill a half inch hole in the desired location. Once you’ve got that drilled, go ahead and install the switch. Peel off the plastic from the high and low plate, install that, and throw the nut on, securing the switch into place. Next we’re going to run the wires down the handlebars and secure them with zip ties along the way. Do that for both sides until you get them down to where you placed the switch now’s a great time to refer to the wiring diagram. The first step in wiring these grip heaters is to connect one wire from each heating element together. So we’re just going to take one wire from each side, cutting it just long enough to reach the switch.
Then strip approximately a half inch off the end of both of those wires and then when you’ve done that, we’re going to twist both of those wires together. Once you’ve done that, you can slide the provided connector over both those wires and then go ahead and crimp it into place. The next step is to run the other two wires coming from the heaters to a good ground. It’s easiest to connect them together, and then use a connector to ground them somewhere on the frame. As you can see, we used one of the air box bolts to ground these wires. Next, locate the source wire with the big white resistor on it, and we’re going to connect that to the high side of the switch. After that, slide the blue connector with the two wires running to the grips onto the center post of the switch. Last, connect the other source wire, that doesn’t have a resistor, to the post on the low side of the switch. It’s a good idea to zip tie the resistor to something metal and not plastic because it does get hot. We’re just going to mount ours along the handlebar. The last step of the install is to connect the system to power. We chose to get a splice connector and just splice into the power wire running to our power outlet.