YAMAHA TTR50 ENDURO LIGHTING KIT INSTALLATION MANUAL
Baja Designs 185 Bosstick Blvd. San Marcos CA 92069 Phone 760.560.2252 Fax 760.560.0383 www.bajadesigns.com
Disclaimer: 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 sellers heirs and assigns, be held liable for consequential damages, nor shall sellers 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. Enduro Lighting Kit: Installation of a Baja Designs Enduro Lighting Kit 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 states 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 drivers 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 at (800) 446-9227 for a rider course near you.
Thank you for purchasing the Baja Designs TTR50 Enduro Lighting Kit. TTR50s come equipped with lighting coils from the factory so no aftermarket or rewound stator is required. This kit can be installed on bikes with both the big bar setup and the stock handlebar setup. Bikes equipped with the GYT-R handlebar kit must run the lower bar-clamps in the rear holes (mounted either way) to provide clearance for the headlight. 1. Remove the front fender/number plate plastic. 2. Remove the seat/body plastic assembly & fuel tank. 3. Carefully trim the front number plate from the front fender. Cut along the transition line between them. A Dremel tool with a slotting bit works excellent for this. When done, reinstall the front fender. Note that the front fender does not require the number plate mounting to remain firmly attached to the motorcycle. If youre running the GYT-R handlebar kit, the front fender extension plate should not be used. 4. Optional Taillight Installation: If youre installing the headlight-only version of this kit you may skip this step. Hold the taillight up to the underside of the rear fender and use the taillight holes as a drill template to drill two holes in the fender plastic as shown in Photos 1 & 2. Use the two button-head Allen bolts & hardware provided to secure the taillight to the fender. The fender will get remounted and the wires attached in a later step.

Photo 1

Photo 2
Photo 3 5. Optional Brake Light Switch Installation: If youre installing the headlight-only version of this kit you may skip this step. Drill a small hole in brake pedal as shown in Photo 3 for the brake switch spring to attach to. Once drilled, attach the brake switch and bracket as shown in Photo 4. Adjust its position so the switchs plunger cannot be pulled to its maximum when the

Photo 4

pedal is pressed. The wires from the switch should be pointed in toward the frame. Theyll get attached in a later step. 6. Power Switch Installation: Attach the high/low/off thumb switch to the handlebar next to the left grip and factory kill switch. If the bike is equipped with stock handlebars, youll need to wrap the spot where the switch will attach with several layers of tape to allow the switch to be clamped tightly. Zip-tie the wire down along the bottom of the handlebar (so tie-downs cant crush it) and over the front of the top triple-clamp. The stock kill switch must be retained. The kill button on the provided headlight switch will not function to kill the motor for this installation. 7. Wiring Harness Installation: Locate the main wiring harness provided with the kit. Attach the single 4-wire connector from the Baja Designs wiring harness to its corresponding mate from the switch you installed in the previous step. The two male connectors from the switch will remain unplugged for this installation. Route the harness back along the right side of the bike following the factory harness and its guides. Attach the ring terminal from the Baja Designs harness to the same coil-mounting bolt that the factory wiring harness grounds to. Locate the white 2-wire connector in the stock wiring harness that mates the thermo switch (small black box mounted on the left side of the steering head) to the main harness. Unplug this connector. Attach the two matching plastic connectors from the Baja Designs harness to both of these connectors from the stock harness you just unplugged. Route the remainder of the Baja Designs harness toward the rear of the bike along the right side of the frame. See Photo 5. These are the taillight and brake switch wires. If you are installing the headlight-only version of this kit, simply leave these wires unplugged and zip-tied up, then skip to Step 8. Taillight Attach the red & green wires with male & Photo 5 leads female connectors from the Baja Designs harness to the two wires from the brake switch Photo 6 as shown in Photo 6. Zip-tie the wires to the frame so they cannot melt on the exhaust pipe. Well attach the three female connectors (Photo 5) from the harness to the taillight in the final step when the seat & body plastic assembly is reinstalled. Secure your wiring with zip ties.

8. Headlight Installation: The headlight attaches to the tops of the fork tubes using brackets and also to the handlebars using zip-tie clearance spacers. The length of the upper spacers versus the handlebar position in its clamp determines where the headlight beam will project. These spacers can be cut and shortened if necessary to properly aim the headlight. With the GYT-R handlebar setup, the lower handlebar clamps must be attached using the rear holes (in either position) to provide clearance for the headlight. Remove the two bolts that Photo 7 attach the fork tubes to the upper triple clamp. Install the provided yellow green black brackets as shown in Photo 7 and reinstall the bolts. Locate the yellow, green, & black wires with small shrinkwrapped terminals from the Baja Headlight Designs wiring harness. These brackets wires attach to the three tabs that are located just inside the opening of the black rubber headlight backing cover. Looking at the back of the headlight, from left to Photo 8 right they attach yellow, green, then black. See Photo 7. Attach the lower headlight holes to the brackets using the provided 6x16 bolts, washers, & Zip-tie nuts as shown in Photo 8. spacers Attach the upper headlight holes to the handlebar using 2 zipties and the 2 provided clearance Headlight spacers as shown in Photos 8 & 9. bracket

Photo 9

Wraps around handlebar
Attaches to headlight plastic
9. Optional Taillight Wiring: If youre installing the headlight-only version of this kit, go ahead and reassemble the bike. Reinstall the fuel tank. The taillight connections should be made prior to installing the seat/body plastic assembly. Attach the black wire from the taillight to the black wire from the Baja Designs harness. Attach the green wire from the taillight to the green/blue wire from the Baja Designs harness. Attach the red wire from the taillight to the red wire from the Baja Designs wiring harness. Reinstall the seat/body plastic assembly. Secure the taillight wires to the frame with a zip-tie. Installation is now complete. The lighting system will function anytime the engine is running unless the power switch is in the off position. If you have any questions or need troubleshooting assistance please call Baja Designs at 760.560.2252 or email info@bajadesigns.com

YAMAHA TTR50 DUAL-SPORT KIT INSTALLATION MANUAL
Baja Designs 185 Bosstick Blvd. San Marcos CA 92069 Phone 760.560.2252 Fax 760.560.0383 info@bajadesigns.com
Disclaimer: 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 manufacured 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, competetion, 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 sellers heirs and assigns, be held liable for consequential damages, nor shall sellers 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 states 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 drivers 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 (9227) for a rider course near you.
Thank you for purchasing the Baja Designs TTR50 Dual Sport Lighting Kit. TTR50s come equipped with lighting coils from the factory so no aftermarket or rewound stator is required. This kit can be installed on bikes with both the big bar setup and the stock handlebar setup. Bikes equipped with the GYT-R handlebar kit must run the lower bar-clamps in the rear holes (mounted either way) to provide clearance for the headlight. 1. Remove the front fender/number plate plastic. 2. Remove the seat/body plastic assembly & fuel tank. 3. Carefully trim the front number plate from the front fender. Cut along the transition line between them. A Dremel tool with a slotting bit works excellent for this. When done, reinstall the front fender. Note that the front fender does not require the number plate mounting to remain firmly attached to the motorcycle. If youre running the GYT-R handlebar kit, the front fender extension plate should not be used. 4. Taillight Installation: Remove the two cloth sleeves and the two black rubber plugs from the ends of the sub-frame. Mount the taillight to the rear sub-frame using the attached rubberized clamps. Position the taillight so the fender plastic, when installed, covers the lens completely. There will be a third mount for the taillight that well attach in a later step. 5. Brake Light Switch Installation: Drill a small hole in brake pedal as shown in Photo 1 for the brake switchs spring to attach to. Once drilled, attach the brake switch and bracket as shown in Photo 2. Adjust its position so the switchs plunger cannot be pulled to its maximum when the pedal is pressed. The wires from the switch should be pointed in toward the frame. Theyll get attached in a later step.

Photo 1

Photo 2
6. Switch Panel and Front Wiring Installation: Attach the switch to the handlebar next to the left grip and factory kill switch as shown in Photo 3. If the bike is equipped with stock handlebars, youll need to wrap the spot where the switch will attach with several layers of tape to allow the switch to be clamped tightly. Zip-tie the wire down along the bottom of the handlebar (so tie-downs cant crush it) and over the Photo 3 front of the top triple-clamp. Well plug in the wires in a later step. Note that the stock kill switch must be retained. The kill button on the switch panel will not function to kill the motor for this installation. 7. Wiring Harness Installation: Locate the wiring harness (gray cable) provided Gray cable in the kit. One end of the gray cable will have a single plastic 6-pin connector with a sheathed orange wire along side it. Attach this connector to its corresponding mate from the wiring you installed in the previous step. Leave enough slack so the steering can turn freely without pulling on the wiring. Route the gray cable back along the Photo 4 right side of the frame following the stock wiring harness guides. Cross the wiring harness to the left side of the frame behind the rear shock as shown in Photo 4. 8. Rear Connections: Locate the stock rectifier/regulator (metal finned box) mounted to the left side of the sub-frame. Unplug the green plastic connector that attaches to it. Attach the two plastic 4-wire connectors from the Baja Rectifier/regulator Designs harness to the regulator connections and to the green connector you Taillight unplugged from it. See Photo 5. Photo 5 connection Attach the 6-pin connector from the Baja Designs wiring harness to its corresponding mate from the taillight as shown in Photo 5.

Rear Connections (continued) Route the sheathed white & blue wire pair from the Baja Designs wiring harness forward with the gray cable (See Photo 4) and attach them to the two wires from the brake light switch. 9. Headlight Installation: The headlight attaches to the tops of the fork tubes using brackets and also to the handlebars using zip-tie clearance spacers. The length of the upper spacers versus the handlebar position in its clamp determines where the headlight beam will project. These spacers can be cut and shortened if necessary to properly aim the headlight. With the GYT-R handlebar setup, the lower handlebar clamps must be attached using the rear holes (in either position) to provide clearance for the headlight. Attach the red & orange wire pair from the Baja Designs wiring harness to the terminals on the flasher marked X & L respectively. Attach the purple/red & pink wire pair from the Baja Designs wiring harness to the two terminals on the horn. Polarity is unimportant. Attach the yellow & black wire pair from the Baja Designs wiring harness to the yellow & black wires from the relay (black cube mounted behind headlight.) Attach the single orange wire from the gray cable to the orange wire from the relay. Remove the two bolts that attach the fork tubes to the upper triple clamp. Install the provided brackets and reinstall the bolts. Attach the lower headlight holes to the brackets using the provided 6x16mm bolts, washers, & nuts. See Photo 6. Attach the upper headlight holes to the handlebar using two zip-ties and the two provided clearance spacers as shown in Photos 6 & 7.

Photo 6

Photo 7

Wraps around handlebar

Zip-tie spacers Headlight bracket Attaches to headlight plastic
Note that the black/white & blue/white (male) wires from the switch panel will not be used and should remain unplugged for this installation.
10. Taillight Mounting: The taillight must be bolted to the rear fender plastic to keep it from moving. Reinstall the fuel tank and seat/body plastic assembly. Use the pre-drilled hole in the taillight (between the two clamps) Countersunk Photo 8 as a guide to drill a single hole bolt & bezel up through the rear fender plastic. washer Insert the provided x spacer between the taillight and fender plastic in the spot you drilled the hole. Slide the bezel washer onto the 6x35mm-countersunk bolt and insert it through the fender, spacer, & taillight holes. Attach the nut & 6x18 washer to the bolt under the fender and tighten. See Photo 8. The kit installation is now complete. Make certain your wiring is properly secured with zip-ties and that it cannot be pinched, crushed, or burned. On the TTR50, the entire kit except for the headlight will function without the engine running. The headlight is powered via its own coil and will turn on any time the engine is running. Proceed to the next section to test the switch functions.

System Checkout: The turn signal switch in this kit controls both the lighting and ignition functions in one compact package. Using the lighting selector, push the switch to the second P position. The taillight should come on and the brake light, turn signals and horn should be operational. Because the headlight runs on its own output from the stator, it will not come on until the engine is running. The third H switch position allows the high/low button to function. Note: The kill button on the switch panel will not function to kill the motor for this installation. The stock kill switch must be retained.
Engine kill button Headlight on position High beam indicator light

Parking light position

Off position Main power switch Horn button

Turn signal switch

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 means early failure. Make sure all the silicone rubber connector boots and the connectors are pushed firmly together and no bare metal is exposed.
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. Harness connection is poor. Make sure the rectifier/regulator connectors are fully seated. Battery is dead. Measure voltage with voltmeter. The Turn Signals Won't Come On, or Won't Flash The wires on the flasher are connected backward. The red wire goes to the terminal labeled "X" and the orange wire goes to L. Check the 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 Short the two leads together at the brake switch. If the brake light comes on, either the brake switch is defective, or is not properly adjusted. Everything Works Except the Headlight Make sure the orange wire from the relay is properly connected to the orange wire from the gray cable. 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.