KLX450R Dual Sport Kit
Kawasaki KLX450R
Dual Sport Kit Installation Manual
Baja Designs ♦ 185 Bosstick Blvd. ♦ San Marcos ♦ CA ♦ 92069
Phone 760.560.2252 ♦ Fax 760.560.0383
www.bajadesigns.com
Page 1 of 13
Warranty: Baja Designs manufactures its own products as well as resells
products manufactured by others. Baja Designs makes no express or implied
warranties on products not manufactured by Baja Designs including without
limitation any warranties or merchantability and fitness for a particular purpose.
We will however, pass on all warranties made by the manufacturer, who has the
sole responsibility for performing such warranties. Baja Designs will repair or
replace any item manufactured by us that we judge to be defective in
workmanship or material within 30 days of shipment. We will not be responsible
for any indirect or consequential damages in connection with defective
merchandise. Products used in racing, competition, or damaged by crash,
abuse, or misuse are not warrantable.
Indemnification: Buyer hereby acknowledges motorcycle riding is a dangerous
sport and that the products and/or supplies purchased from Baja Designs are
used in an inherently dangerous activity that may endanger life and limb; and in
no event shall the seller, or the seller’s heirs and assigns, be held liable for
consequential damages, nor shall the seller’s liability on any claim for damages
arising out of or connected with the sale, delivery, or use of purchased products
and/or supplies exceed the purchase price of the products and/or supplies.
Dual-Sport Kit: Installation of a Baja Designs Dual-Sport Kit by itself does not
make an off-road motorcycle street legal. Each state has different equipment
requirements for street legal motorcycles, including but not limited to such items
as DOT approved tires, left and right side mirrors, speedometers, quiet exhaust,
chain guards, and side reflectors. Contact your state’s Department of Motor
Vehicles or highway patrol for a comprehensive list of equipment that is required
for street motorcycles before riding your bike on the street.
Street Riding: Riding a motorcycle on the street is very different than off-road
riding and requires special skills not learned off-road. Most states require an
additional license beyond an automobile driver’s license to operate a motorcycle
on the street. Make sure to have the proper licensing and skills before riding
your bike on the street. Baja Designs recommends contacting the Motorcycle
Safety Foundation (800 446 9227) for a rider course near you.
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The stator on the KLX450R is wound with two separate lighting coil outputs. One
of these outputs will be used to power the headlight exclusively on its own AC
circuit. The remaining output charges the battery, which will be used to power
the taillight, turn signals, and horn.
Note that you have the option to run the stock headlight with this dual sport kit.
1. Remove the seat, fuel tank, and side panels.
2. Unplug and remove the stock headlight.
3. Taillight Installation: The Baja Designs taillight will run in conjunction
with the stock taillight for this installation.
Start by removing the first wire guide that the
stock taillight wires pass through near the
end of the fender. Once removed, trim off
the remaining molded mounting boss as
shown in Photo 1.
Drill three ¼” holes in the fender and use the
provided countersunk mounting hardware to
attach the Baja Designs taillight as shown in
Photo 2. The rear edge of the LED cluster
should line up with the rear edge of the
fender. Route the wires forward between the
plastics to the left of the front mounting bolt.
We’ll attach them in a later step.
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4. Turn Signal Installation: Drill a 7/16” hole
in each side of the fender plastic in the
locations shown in Photo 3. Install the rear
turn signals and route the wires forward as
shown in Photo 4.
5. Brake light Switch: The KLX uses a hydraulic operated switch to
activate the brake light. Installation of this switch requires bleeding the
rear brake system. If you do not feel competent performing this task
please refer it to a qualified mechanic. An improperly bled brake can
lead to rear brake failure.
Caliper Guard Modification: The hydraulic
brake switch replaces the banjo-bolt that
attaches the rear brake hose to the caliper.
Because of its larger size, the plastic caliper
guard must be relieved slightly to provide
clearance. Remove the caliper guard and
modify as shown in Photo 5.
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Brake switch Installation: Remove the
banjo-bolt that attaches the rear brake hose
to the caliper. Replace this bolt with the
provided hydraulic switch as shown in Photo
6. Be sure to retain the upper and lower
crush washers when installing the switch.
Brake Bleeding: Do not begin this process unless you have a fresh bottle
of brake fluid.
Remove the reservoir cap from the rear brake master cylinder. Put the
box end of a 10mm wrench over the bleed nipple and install the supplied
bleed tubing tightly over the nipple. Position a loop in the hose above the
nipple with the other end of the hose in the container to catch the fluid.
Crack the bleed nipple open about a quarter turn keeping the loop in the
hose vertical. Slowly depress the brake pedal to fill the hose with fluid.
Pump slowly until you have brake fluid extending up into the loop, then
you can pump the pedal fairly aggressively to drive air out of the system.
The fluid above the bleed nipple will prevent air from re-entering the
system. Do not let the reservoir go dry – add fluid as needed. Pump the
pedal until the there are no more bubbles then close the nipple. When
done, double check that the pedal is firm and works properly.
Brake switch Wire Extension Installation: Locate the 2-wire extension
provided in the kit parts bag. Attach the female end to the two male
terminals from the brake switch and route it forward following the stock
brake hose. Route the wire extension to the master cylinder following the
curve of the brake hose using a few zip-ties. We will attach the wires in a
later step. Reinstall the modified caliper guard. See Photos 7 & 8.
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6. Kill Button: Unplug the stock kill button (white connector attached to
steering head) and remove it from the handlebar.
We will remove the connector from the stock kill button and use it to
interface the Baja Designs front harness assembly with the stock wiring
harness.
Terminal Removal & Reinstallation: Using
a skinny pointed object, push in the small tab
in the kill button connector that holds in the
metal terminal attached to black/white wire.
Tug on the black/white wire from the back of
the connector while the tab is pressed and
the metal terminal will release from the
connector. See Photo 9. Once removed,
replace it with the black/white wire from the
front harness assembly provided with the kit.
Remove the black/yellow wire from the kill
button connector and replace it with
blue/white wire from the front harness assembly.
7. Turn Signal Switch Installation: Install the turn signal switch on the left
handlebar next to the grip. The switch has two screws that mate the two halves
together. Note: Install the two rubber shims provided on the back half of the turn
signal switch body. Do not over tighten these screws, as too much force can
strip the body of the switch. The clutch perch may have to be moved to the right
to make room for the switch. Zip-tie the wires along the bottom of the handlebar
(so tie-downs can’t crush them) and over the front of the top triple clamp.
Key Switch Installation: Mount the key switch unit off one of your
handlebar clamp bolts or upper triple clamp bolts. Make sure it is easy
to reach as this will now function as your kill switch for the bike. Make
sure the key switch and wires are not contact any part of the chassis.
Middle Wiring Harness Installation: Locate the black
cable with the white plastic multi-pin connectors at each end provided with the
kit. Position one of the multi-pin connectors (doesn’t matter which – both
ends of the middle harness are identical) so it sits just to the right of the
steering head near the black connector from the switch panel. Route the
middle harness back along the right side of the frame following the stock
wiring harness to the area along the right side of the airbox.
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8. Rear Wiring Harness Installation & Connections: Locate the rear
wiring harness provided with the kit. It has a white plastic multi-pin
connector with several sheathed power leads extending from it.
a. Attach the 6-pin connector from the
rear wiring harness to its
corresponding mate from the middle
harness as shown in Photo 10.
b. Unplug the white plastic 2-wire
connector that mates the fused lead
to the rear wiring harness. Remove
the 15A fuse and attach the ring
terminal from the fused lead to the
positive side of the battery.
c. Attach the remaining black un-fused
ring terminal to the negative side of
the battery.
d. Push the white 2-pin connector through the gap between the
fender and sub-frame and reattach it to its corresponding mate
from the rear wiring harness.
e. Attach the white plastic 3-pin connector from rear wiring harness
to its corresponding mate from the taillight.
f. Attach the green & black wire pair to the two wires from the right
rear turn signal. If you are using standard (non-LED) signals,
polarity is unimportant. If you are using LED signals, attach the
green wire from the harness to the designated positive wire from
the signal (yellow or red on Baja Designs LED signals.)
g. Attach the brown & black wire pair to the two wires from the left
rear turn signal. If you are using standard (non-LED) signals,
polarity is unimportant. If you are using LED signals, attach the
green wire from the harness to the designated positive wire from
the signal (yellow or red on Baja Designs LED signals.)
h. Route the red & blue wire pair down the sub-frame and attach
them to the two wires from the brake switch extension you
installed in step 5. Zip-tie the wires away from the exhaust.
i. Replace the 15A fuse.
The rear wire connections are now completed. Secure your wiring with zip-ties.
9. Headlight Connector: The relay switch wiring from the Baja Designs
headlight will interface with the stock wiring harness via the stock
headlight connector. We will remove the connector from the stock
headlight and attach it to the Baja Designs headlight to make this
connection. Even if you plan to use the stock headlight with the
dual sport kit, follow this step. The next step goes into detail about
stock headlight installation.
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Terminal Removal & Reinstallation: Using a sharp pointed object or a
jewelry screwdriver, push in the small tabs in the stock headlight
connector that hold the metal terminals as shown in Photo 11. Tug on the
corresponding wire from the back of the connector while the tab is pressed
and the metal terminal will release from the connector. Remove all three
terminals from the headlight connector. Once removed, attach the
headlight connector to the blue and green wires from the Baja Designs
headlight as shown in Photo 12. The middle position of the connector will
not be used. Take extra care to make sure you insert the blue and green
wires into the proper positions in the connector. The headlight will not
function if these terminals are reversed.
10. Stock Headlight Installation: The stock KLX450 headlight comes
equipped with a 35/35w high/low halogen bulb so it can be utilized with
the dual sport kit. If you choose to use it, the electronics and wiring
mounted in the Baja Designs headlight must be removed and remounted
in the stock light. The front turn signals will mount to the upper triple
clamp via supplied brackets.
a. Unplug the wiring that attaches to the horn, flasher, turn signals,
and headlight relay mounted behind the Baja Designs headlight.
Remove all of these items from the headlight.
b. Remove the rubber dust cover from the back of the stock
headlight lens and unplug the connector that attaches to the back
of the bulb. Remove the stock wiring from the dust cover.
c. Mount the relay switch and its wiring and the turn signal flasher to
the bracket above the lens. Attach the H4 connector from the
relay to the three prongs from the stock bulb. Reinstall the dust
cover with the relay wiring passing through the side. The original
wire passage hole will not be used.
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d. Mount the horn to one of the studs that attaches the stock
computer. You will need to bend the bracket slightly for
clearance.
e. Attach the provided brackets to the turn signals. They will attach
to the triple clamp as shown in Photo 13.
f. Reattach the front wiring harness to the electronics and
accessories.
Orange w/white tracer, red & green pair – flasher.
Red, red & purple pair – horn.
Yellow & black wire pair – headlight relay.
Green & black wire pair – right turn signal.
Brown & black wire pair – left turn signal.
11. Headlight Installation & Connections:
• Attach the black multi-pin connector from the headlight to its
corresponding mate from the switch panel assembly.
• Attach the white multi-pin connector from the headlight to its
corresponding mate from the middle wiring harness.
• Attach the plastic relay connector from the headlight (installed in
step 10) to its corresponding mate from the stock wiring harness.
• Attach the light green 4 pin connector to the key switch assembly.
• Attach the headlight to the fork tubes. Turn the streeing from side
to side to verify that the wiring does not bind or get caught in the
steering stops.
The following connections have been pre-made prior to shipping:
Flasher: The orange w/white tracer, red & green pair are attached to the red and black
wire pair from the flasher.
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Horn: The red, red & purple pair attach to the two terminals from the horn. Polarity is
unimportant.
Front Turn Signals: The green and black wire pair attach to the two wires from the
right turn signal. The brown and black wire pair attach to the two wires from the right
turn signal. Note: When using LED turn signals polarity is important so be sure to
match the black ground wire from the front harness to the ground on the LED turn
signals. When using incandescent signals polarity is unimportant.
Relay: The black & brown pair, yellow, and green w/black tracer all run to the 3 pin
male white plastic connector and on to the relay switch.
ACEWELL: All kits now come prewired with a
triangular female 3-pin plug which allows you to easily
power certain Acewell speedometer/tachometer units.
Contact Baja Designs at 760-560-BAJA for more info.
To see the full line of Acewell speedometers visit
www.BajaDesigns.com
Photo 14
The wiring installation is now completed.
Proceed to next section to test your work.
Photo 15
Key Switch: The Key Switch is
used to control both ignition and
lighting functions. The key switch
must always be in the “Ignition”
position indicated by the red dot
on the Key Switch for
the bike to run or the parking
lighting to operate. In the
“Ignition” position your running
light and taillight should turn on
and you should be able to operate
your turn signals, headlight and
horn. This also allows you to start
your bike.
System Checkout: The
handlebar switch controls the
lighting functions only. The lower
“dot” position will allow your
parking lights to turn on when the
key switch is turned on. This
position will also allow the use of
the turn signals, brake light,
headlight, and horn. The first light
position will turn on your low
beam and the top light position on
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the switch will turn on your high beam. When the high beam is selected the top
indicator light will illuminate to remind you the high beam is selected.
Note: The Key Switch must be on for the bike to run or any lighting functions to
operate.
If everything is working properly congratulate yourself on a job well done. If not,
don't worry, it's not rocket science and we should be able to figure it out. See the
trouble-shooting list in a later section.
Wrapping It Up: It is important that all the wires be properly routed and secured.
Double-check the photos and sketches with regards to wire routing. Make sure
the wires do not pass over any sharp edges, are pulled overly tight, or can be
crushed by the seat, tank, fender, etc. Use all the zip ties provided to securely
fasten the wires. Any unwanted movement or chafing suggests early failure
when off the road. Make sure all the silicone rubber connector boots and the
connectors are pushed firmly together and no bare metal is exposed. Install the
seat, tank, and side panels, go down to your local DMV, and then go roost!
Removing and reinstalling the kit: To remove the kit, simply unplug the
connector that mates the middle harness to the rear harness and the connector
that joins the battery leads to the rear harness. Remove the “dual sport rear
fender” with the rear harness still attached to it and reinstall a stock fender (not
supplied.) The middle harness stays on the bike. The front signals can unbolt
and unplug individually.
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TROUBLESHOOTING
Nothing Happens When You Turn the Power Switch On.
• Fuse is blown. Check for bare wire or terminal shorting against the frame or
another wire.
• Multi-pin connector not properly connected.
• Battery connection poor. Make sure the connectors are fully seated.
• Battery is dead. Measure voltage with voltmeter.
• Poor connection at the blue wire junction and the fuse lead.
The Turn Signals Won't Come On, or Won't Flash
• Check turn signal wire connections.
• Make sure you have connected the correct wires to the turn signals. Check
instructions.
• Battery voltage is low. If the battery voltage is low, the turn signals won't flash,
or will flash very slowly. Running the bike will cure this as well as charge the
battery.
The Brake Light Won't Come On
• The rear brake system is not properly bled.
• Short the two leads together at the brake switch. If the brake light comes on,
either the brake switch is defective, or the brake system is not properly bled.
Everything Works Except the Headlight
• The headlight selector switch must be on low beam or high beam.
• The engine must be running for the headlight to operate.
• Make sure the three prong connector is correctly plugged in and that the wires
leading to it are plugged into the harness.
• Does the high beam indicator come on when the bike is running and high beam
selected? If so, the headlight bulb is burned out or defective.
If you still need assistance, call Baja Designs at (760) 560 2252.
Maintenance: Occasionally examine the wires in your lighting system to make
sure they are not chaffing or binding so that they don't cause you a problem
when you're out on the trail or on the road. A well routed, properly secured wiring
system is key to getting long life and trouble free performance from your
conversion kit.
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Baja Designs • 185 Bosstick Blvd. • San Marcos • CA • 92069
Phone 760.560.2252 • Fax 760.560.0383 • info@bajadesigns.com
www.bajadesigns.com
October 2011
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