How to Install LED Light Bars on Your Jeep or UTV

By Dave Barrette, Owner of Bold Off-Road

Night riding changes everything. Stock headlights barely light the path ahead. You need more visibility to stay safe and enjoy the experience.

At Bold Off-Road in Coggon, Iowa, we've installed LED light bars on hundreds of Jeeps and UTVs over 25 years. This guide shows you how to install LED light bars properly for maximum performance.

Choosing Your Light Bar Location

Your mounting location affects both performance and installation difficulty.

Roof Mount - Best visibility at distance. Works well for high-speed trails. Installation takes 2-3 hours.

Bumper Mount - Easy to install. Great for close-range visibility. Can get damaged on technical trails. Installation takes 1-2 hours.

Windshield Mount (Jeeps) - Uses existing A-pillar mounting points. Good visibility without roof drilling. Installation takes 2-3 hours.

"We install more roof-mounted bars than any other location," says Dave Barrette, owner of Bold Off-Road. "The height gives you better distance vision. We recommend 30-40 inch bars for most UTVs and 40-50 inch bars for Jeeps."

Tools and Materials You Need

Basic installation requires:

• Socket set (10mm and 13mm most common)
• Allen wrench set
• Wire strippers and crimpers
• Electrical tape and zip ties
• Drill and bits (if needed)
• Multimeter for testing

Quality light bars include mounting brackets, wiring harness, relay, switch, and hardware.

Step-by-Step Installation Process

Step 1: Test Your Light Bar

Always bench test before installation. Connect the light bar directly to your battery using the provided wiring. Verify it works properly. Finding defects after installation wastes hours.

Step 2: Mount the Brackets

Position your mounting brackets according to instructions. Most UTV roof mounts use existing roll cage holes. Jeep windshield mounts attach to A-pillar bolts.

Mark your mounting points carefully. Use a level to keep everything straight. Attach brackets loosely for adjustments later.

Step 3: Attach the Light Bar

Get help lifting the bar. Slide it into the mounting brackets. Point the beam downward about 5 degrees to project light onto the trail. Tighten all mounting hardware once aimed correctly.

Step 4: Route Your Wiring

This step takes the most time. Route wires from the light bar to your battery and switch.

For UTVs: Run wires along the roll cage using zip ties every 12 inches. Keep wires away from moving parts and hot exhaust. Use an existing firewall passthrough or drill a new hole with a rubber grommet.

For Jeeps: Remove A-pillar trim. Run wires down behind the trim. Pass wires through the firewall near the steering column.

Secure all wiring with zip ties. Leave some slack for movement but don't let wires hang loose.

Step 5: Install the Relay and Switch

The relay prevents your dash switch from handling the full current load. Mount the relay near the battery.

Connect the relay according to the wiring diagram. Red wire to battery positive. Black wire to battery negative or ground. Switch wires run to your cab.

Install your switch in a convenient dash location.

"The relay is the most important safety component," Barrette explains. "Never skip the relay and wire direct to the battery. The full current will overheat your dash switch. Always use the relay that comes with your kit."

Step 6: Make Final Connections

Connect the power wire from your light bar to the relay output. Connect the ground wire to a good ground point. Double-check all connections.

Reconnect your battery. Test the light bar. If it doesn't work, check your fuse first. Then verify all connections.

Light Bar Sizes and Costs

20-30 Inch - Best for ATVs and small UTVs. Cost: $150-300.

30-40 Inch - Best for full-size UTVs. Cost: $200-400.

40-52 Inch - Best for Jeeps and trucks. Cost: $250-500.

Quality matters for off-road vibration and water exposure.

Bold Off-Road Installation Services

We install LED light bars at our Coggon shop. This includes mounting, wiring, testing, and aiming. Installation typically takes 2-4 hours.

We work on all makes: Polaris, Can-Am, Yamaha, Honda, Kawasaki, Jeep, and Toyota.

Frequently Asked Questions

Do I need a special wiring harness?

Yes. Quality light bars draw 10-20 amps. You need a relay-equipped harness with proper gauge wire and inline fuse. Never wire directly to your battery without a relay.

Can I install multiple light bars?

Absolutely. Many riders add smaller pod lights alongside their main bar. Each light needs its own relay and fuse. Most UTVs handle 40-50 amps of lighting accessories safely.

How do I aim my light bar correctly?

Park facing a wall 25 feet away. Turn on the light. The center of the beam should hit the wall at the same height as the light bar or slightly lower. Test on a trail and fine-tune as needed.

Ready to add serious lighting to your Jeep or UTV? Visit Bold Off-Road in Coggon or call (563) 277-8830. We'll help you choose the right light bar and install it professionally.