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Honda CRF250X & ’05-’07 CRF450X Dual Sport Kit Installation Manual

(Part Number: 12-1052)

    

Baja Designs 185 Bosstick Blvd. San Marcos CA 92069

Phone 760.560.2252 Fax 760.560.0383

www.bajadesigns.com 

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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 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 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.

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The stator on the CRF-X’s 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.

1. Remove the seat, fuel tank, and side panels.

2. Unplug and remove the stock headlight.

3. Taillight Installation: The Baja Designs LED

taillight will be run in conjunction with the stock LED taillight for this installation. Remove the two Phillips head bolts and metal bracket underneath the fender that hold the stock LED taillight into place. (The new taillight will utilize these threaded holes to mount to the fender.) Using the metal bracket as a template (see Photo 1), drill two 5/16” mounting holes through the taillight plastic in the positions shown. Once drilled, use the two stock bolts to attach the taillight to the fender. The metal bracket will no longer be used. A small flathead screwdriver can be used to brace the stock LED cluster to help you get the bolts started. See Photo 2. For the forward taillight mount, drill a single ¼” hole through the center of the fender and taillight plastic as shown in Photo 3. There will be about a 1” gap between them. Locate the countersunk bolt, spacer, & bezel washer in the parts bag. Install this bolt with the spacer between the fender and taillight plastic and tighten. Route the taillight wires forward through the trough between the taillight plastic and fender. We’ll attach the taillight wires in a following step.

4. Turn Signal Installation: The rear fender plastic on the CRF is exceptionally thick allowing for excellent rear turn signal mounting locations. Mark the drill locations as shown in Photo 4. Once marked, Drill a 3/8” hole on each side of the fender and attach the turn signals as shown in Photo 5. Position the holes so the top edges of the turn signal stalks line up with the molded ridge in the fender. Route the left turn signal wires so they pass through the gap left by the side panel as shown

Photo 1

3 ¼”

Photo 3

Photo 2

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in Photos 6 & 7. Route the taillight and right turn signal wires forward as shown in Photo 8.

5. Brakelight Switch: The CRF’s use 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. Installation: Remove the banjo-bolt that secures the rear brake line to the rear brake master cylinder. Replace this bolt with provided hydraulic switch as shown in Photo 9. Be sure to retain the upper and lower crush-washers when installing the switch.

Photo 4

Drill here

Photo 5

Photo 9

Photo 6

Photo 8

Photo 7

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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 an 8mm wrench over the bleed nipple and install the supplied bleed tubing tightly over the nipple. Position the loop in the hose above the nipple as shown in Photo 10 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.

6. Turn Signal Switch Installation: Install the switch panel assembly on the left handlebar next to the grip. The stock kill button must be moved to the right side of the clutch perch to make room for the switch panel assembly. (The stock kill button will no longer function once the kit is installed – the kill feature will now be incorporated into the Baja Designs Key Switch.) The switch panel has two screws that attach the two halves. Note: Install the two rubber shims provided on the bottom half of the turn signal switch body. Do not over tighten these screws as too much force can strip out the body of the switch. Route the wires along the bottom of the handlebar (so they can’t get crushed by tie-downs) and over the front of the upper triple-clamp.

Photo 11 7. 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.

8. Middle Wiring Harness Installation: Locate the black

cable with white plastic multi-pin connectors at both ends 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 in front of and on the left hand side of the steering tube. With the handlebars turned fully to the right, route the middle harness down along the left side of the frame. On CRF250X’s cross the middle harness to the

Photo 10

Bleed Nipple Container

Bleed Hose

8mm Wrench

Photo 12

Middle Harness Routing CRF250X

Photo 13

Middle Harness Routing CRF450X

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Photo 15

right side of the bike as shown in Photo 12. Route it along the upper right side of the airbox so the wires terminate at its rear corner. On CRF450X’s route the middle harness along the left side of the bike following the stock harness as shown in Photo 13. Cross it over the top of the carburetor and route it along the right side of the airbox. The multi-pin connector should terminate on top of the airbox near the battery. We’ll attach the connectors in the following steps.

9. Rear Wiring Harness Installation and Connections:

Locate the rear wiring harness provided with the kit. It has a white plastic 6-pin connector with several sheathed power leads extending from it. Attach the 6-pin connector from the rear harness to its corresponding mate from the middle harness.

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.

Attach the white plastic 3-pin connector from the rear wiring harness to its corresponding mate from the taillight.

Attach the green w/ yellow tracer & black wire pair to the two wires from the right rear turn signal. Polarity is unimportant on incandescent turn signal. Note: When using LED turn signals polarity is important so be sure to match the black ground wire on our harness with the ground from your LED signals

Attach the brown w/white tracer & black wire pair to the two wires from the left rear turn signal. Polarity is unimportant on incandescent turn signal. Note: When using LED turn signals polarity is important so be sure to match the black ground wire on our harness with the ground from your LED signals

Route the red & blue wire pair down to the brake light switch and attach the two wires. Polarity is unimportant.

The rear wire connections are now completed. Secure your wiring with zip-ties.

Headlight Connector: The Baja Designs front harness comes with the OEM headlight connector installed. Simply plug this unit into the cooresponding connector in the factory wiring harness. (Photo of connector is shown under step 11 for reference)

Photo 14

Attach ground here

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10. Kill Function Connector: The kill wires from the Baja Designs wiring

harness will interface with the stock wiring harness via the stock kill connector. We will remove two of the stock wires from this connector and replace them with the Baja Designs wires. Note that the stock kill button will no longer function once this step is performed. The kill feature will be incorporated into the Baja Designs key Switch. Terminal Removal & Reinstallation: Locate the stock black three-wire connector that’s attached to the bracket under the odometer (the lower one of the two connectors – see Photo 16) Lift the locking detent tab behind the connector to unplug the side that’s not attached to the bracket. Push down the detent tab that locks the connector half to the bracket and remove the remaining side from the bracket. Using the same tool you used to remove the headlight connector in step 10, remove the black/white and black/green wires from the connector half that was attached to the bracket as shown in Photo 17. Do not remove the black/brown wire from this connector. Locate the black/white and blue/white wire pair from the Baja Designs front harness wiring. They’ll have the same terminals as the wires you removed from the connector. Insert the Baja Designs wires into the connector as shown in Photo 18. Once the wires are installed, reattach the connector to the bracket and then reattach it’s corresponding mate. If you choose, you may now remove the stock kill button by snipping off the stock terminals and pulling the two wires through the factory sheathing.

11. Headlight Installation & Connections:

Attach the black multi-pin connector from the headlight to its corresponding mate from the turn signal switch assembly.

Attach the white multi-pin connector from the headlight to its corresponding mate from the middle wiring harness.

Attach the light green 4 pin connector to the key switch assembly. (as shown below)

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Photo 19

Attach the light green flat 3 pin connector from the Baja Designs front wiring harness into the matching connector from the stock wiring harness.

Connect to mating connector on the factory headlight harness

Photo 20

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 with white tracer and the red & green pair are attached to the red and black wire pair from the flasher. Horn: The red & purple pair and red wire pair attach to the two terminals from the horn. Polarity is unimportant. Front Turn Signals: The green tracer 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 left 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, green w/black, yellow 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

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The wiring installation is now completed. Proceed to the next section to test your work.

Note: When using this kit with a Baja Designs rewound 450x stator you will need to use a H4 Jumper Adaptor to eliminate the relay. All other wiring will remain the same.

Photo 21 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 and horn. This also allows you to start your bike. Because the headlight operates off direct stator output the headlight will not operate unless the bike is running.

Photo 22 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, and horn. Note: The stock 250x/450x uses an AC headlight circuit and the headlight low and high beam will not operate unless the bike is running. With the bike running selecting the first light position will turn on your low beam and the top light position on 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.

Headlight Low Beam On

Parking Light Position

Headlight High Beam On

NOTE: Main Power Controlled by Key Switch

Turn Signal Selector

Horn Button

High Beam Indicator

* Key Switch = Kill Switch for Ignition and Lights

Run/Lighting Power = ON

Ignition/Lighting = OFF

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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. Photo 23

TROUBLESHOOTING

Nothing Happens When You Turn the Key Switch On. • Fuse is blown. Check for bare wire or terminal shorting against the frame or another wire.

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• 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 • Make sure the flasher plug is fully seated. • Check turn signal wire connections. • Note: On LED Signals polarity is important so make sure the turn signals ground is matched with the black wire on the harness. • 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. • Maybe it's on already. Brake and tail connections are reversed. The brake light is already on so there is no increase in light intensity when you activate the brake. • 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. • 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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CRF 250X & ’05-’07 CRF 450X DSK (PART # 12-1052) PARTS LIST CHECKOFF SHEET

□ DSK Headlight –04 Red– Includes the following:

□ Headlight Shell (60-1114) Headlight Lens (60-0002) & Graphic (40-0074)

□ Wired Running Light (60-4006) □ 35/35w H-4 Bulb (13-0011)

□ Horn (12-2001) □ Flasher (60-3008)

□ 2 - Turn Signals (5½” Wires) (60-4185)

□ Adjustable Rubber Strap 4- (60807)

□ Front Harness E w/ Key Switch (12-9031) Male FRS Pins on Ignition Wires

□ Switch relay with Diode & wiring (12-9021)

Individual Parts:

□ LED Taillight (30” Wires w/ 3-Pin Connector) (60-0709)

□ 2 - Turn Signal w/ Nuts & Washers (18” Wires) (60-4185)

□ Switch Panel (12-9028)□ Electric Rear Wiring Harness (20100)

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□ Electric Mid Wiring Harness (22700)

□ License Plate Mount Assembly (60-2070) 1 - BD License Plate Frame 1 - License Plate Backing Bracket 2 - 6x20 Countersunk Bolts 4 - 6x16 Phillips Head Bolts 6 - 6mm Nuts, 6x18 Washers

□ Parts Bag – Includes the following:

Nissin Hydraulic Brakeswitch

□ (12-0104)

□ Misc. Hardware 1 Zip-tie Bundle 4 6x20 Countersunk Bolts, Bezels, 6x18 Washers, 6mm Nuts 1 Brake Bleed Tubing 3 Male & Female Connectors 1 6x35 countersunk bolt

bezel, 5/8x1/2 plastic spacer, 6x18mm washer, 6mm nylock

□ 1 CRF 250X & ’05-’07 CRF 450X DSK (PART # 12-1052) Installation Manual

□ CHECKED BY:________________________________