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

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 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 seller's heirs and assigns, be held liable for consequential damages, nor shall 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 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 (800 446-9227) for a rider course near you.
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.

Photo 1

Stock taillight Molded mounting boss removed
Drill three 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. Well attach them in a later step.

Photo 2

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.

Photo 3

Route left signal wires Photo 4 through fender with stock taillight wires
Zip-tie BD taillight wires to fender here
5. Brakelight Switch: The KLX uses a hydraulic operated switch to activate the brakelight. 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 brakeswitch 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.

Photo 5

Caliper guard relief mod
Brakeswitch 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.

Photo 6

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. Brakeswitch 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 brakeswitch 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.

Photo 7

Photo 8
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 switch panel 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 handlebar switch panel assembly provided with the kit. Remove the black/yellow wire from the kill button connector and replace it with blue/white wire from the switch panel assembly.

Photo 9

7. Switch Panel Installation: Install the switch Panel Assembly to the left handlebar next to the grip. The switch panel has two screws that attach the two halves. Do not over tighten these screws as too much force can strip out the body of the switch. Zip-tie the wires along the bottom of the handlebar and over the front of the top triple-clamp. Reattach the white plastic kill connector to its corresponding mate from the stock harness.
8. 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 (doesnt 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.
9. 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. Attach the 6-pin connector from the rear wiring harness to its Photo 10 corresponding mate from the middle harness as shown in Photo 10. 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. Attach the remaining black un-fused ring terminal to the negative side of the battery. 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. Attach the white plastic 3-pin connector from rear wiring harness to its corresponding mate from the taillight. 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.) 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.) Route the red & blue wire pair down the sub-frame and attach them to the two wires from the brakeswitch extension you installed in step 5. Zip-tie the wires away from the exhaust. Replace the 15A fuse. The rear wire connections are now completed. Secure your wiring with zip-ties.

10. 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. 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. Photo 11 Green wire Photo 12
Stock headlight connector

Blue wire

Note orientation of connector when inserting wires
11. 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. 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. 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. 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. Mount the horn to one of the studs that attaches the stock computer. You will need to bend the bracket slightly for clearance. Attach the provided brackets to the turn signals. They will attach to the triple clamp as shown in Photo 13. Reattach the front wiring harness to the electronics and accessories. Red & orange wire pair flasher. Red/purple & pink wire pair horn. Yellow & black wire pair headlight relay. Green & black wire pair right turn signal. Brown & black wire pair left turn signal. Photo 13

12. 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 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 red and orange wire pair attaches to the two terminals from the flasher unit. Horn: The red/purple & pink wire 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. Relay: The black and yellow wire pair attaches to the black & yellow wires from the relay switch. The wiring installation is now completed. Proceed to the next section to test your work.
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 brakelight, turn signals and horn should be operational. In this position the bike will also now start. 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 lighting selector switch must be in positions P or H for the bike to run.
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 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.

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 brakelight 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. 185 BOSSTICK BLVD SAN MARCOS CA 92069 760.560.2252 800.422.5292 WWW.BAJADESIGNS.COM