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Yamaha TTR225 Dual Sport Kit Installation Instructions

(Part Number: 12-1013)

185 Bosstick Blvd. San Marcos California 92069

Phone (760) 560-2252 Fax (760) 560-0383

info@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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1. Remove the seat, side panels, front number plate and fuel tank. 2. Taillight Installation: Remove the existing cover on the rear fender. Drill two

3/16 mounting holes as shown in Photo 1. The position of the holes is determined by carefully positioning the taillight assembly over the opening and transferring the top mounting hole locations to the fender. You want to make sure the holes are as close to the edge of the well as possible and just miss the plastic molding when drilling through the fender. Note location of holes relative to the opening it the Photo 1. Drill a 3/8” hole at the left side of the well for wire routing. Using the 4 mm screws provided, temporarily install the taillight over the opening so that you can determine the location for drilling the bottom license plate mount. Drill the license plate mount hole to 1/4” and mount the taillight assembly over the well, running the wires through the routing hole and along the left seat frame rail. Make sure to install the 6x16 mm fastener for the license mount from the bottom up to minimize the chance for the tire to grab it.

Drill two places, 3/16 diameter.

Photo 1

Drill 3/8” hole here for wire routing

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3. Turn Signal Installation: The TTR 225 has factory turn signal mounts built in. These mounts must be drilled out (7/16”) as shown in Photos 2 & 3. Install the turn signals to these mounts and run the wires forward along the left and right frame rails.

4. Brake Light Switch Installation: Drill a 1/8” hole in the brake lever as shown in Photo 4. The brake light switch bracket mounts under the right side case mounting just above the swingarm pivot. We will adjust the switch in a later step.

Photo 2

Photo 3

Photo 4

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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.

Photo 5

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.

5. Middle Wiring Harness Installation: Locate the black cable with the white

plastic multi-pin connectors at both ends provided with the kit. Position one of the multi-pin connectors (doesn’t matter which – the mid harness is identical at both ends) so that it sits just to the left of the steering head tube near where the black switch panel connector terminates. Route the black cable down along the left side of the frame following the stock wiring harness. Route the cable to the area on top of the airbox. We’ll attach the connectors in later steps.

Middle Harness Photo 6

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6. Rear Wiring Harness Installation & Connections: Make sure the 3-position

power switch on the switch panel is in its lowest “off” position before making the following 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 wiring 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 3-pin plastic connector from the rear wiring harness to its corresponding mate from the taillight.

Attach the green and black wire pair to the two wires from the right rear turn signal. Polarity is unimportant.

Attach the brown and black wire pair to the two wires from the left rear turn signal. Polarity is unimportant.

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

The rear wiring is now completed. Secure your wiring with zip-ties.

7. Front Wiring Connections & Headlight Installation: 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 headlight to the fork tubes. Turn the steering from side to

side to verify that the wiring does not bind or get caught in the steering stops.

*Note that the kill function on the switch panel will not be utilized for this installation. The black/white & blue/white wire pair from the front harness will remain unplugged. These wires are not hot leads.

The following connection have been made prior to shipping:

Flasher: The orange w/white tracer, and the red & green pair are attached to the red and black wire pair from the flasher.

Horn: The red, and 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 left turn signal. Note:

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Run/Lighting Power = ON

Ignition/Lighting = OFF

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 the 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

The wiring installation is now completed!! Proceed to next section to check your work.

Photo 7

Brake Light Switch Ad 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, brakelight, headlight, and horn. 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.

Photo 8

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

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Note: The Key Switch must be on for the bike to run or any lighting functions to operate. Adjustment: Adjust the brake switch in its bracket so the brake light comes on when the pedal is near the end of its throw. Do not adjust the switch too sensitive as this can lead to premature switch failure. Wrapping It Up: It is important that all the wires be properly routed and secured. 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. Make sure all the silicone rubber connector boots and the connectors are pushed firmly together and no bare metal is exposed. Put on the seat, tank, and side panels, go down to your local DMV, and then go roost!

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TROUBLESHOOTING Nothing Happens When you push the lighting selector to the first position. • Is the ignition key on? • Fuse is blown. Check for bare wire or terminal shorting against the frame or another wire. • Multi-pin connector not properly connected. • Battery is dead. Measure voltage with voltmeter, or connect a 12 volt light across it. 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". • Check turn signal wire connections. • Make sure you have connected the correct wires to the turn signals. Check instructions. The Brake Light Won't Come On •. The rear brake switch is not properly adjusted. • 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. Check the red and blue taillight connections. • Short the two leads together at the brake switch. If the brakelight comes on, either the brake switch is defective, not adjusted properly. Everything Works Except the Headlight • 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 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. The light bulbs take a beating on a dirt bike, especially that of the rear tail lights. The continuous vibration and impact can cause the bulb contact to prematurely oxidize, causing the bulb to fail. Occasionally remove the bulbs (taillight and turn signals) and scrape the soft contact at the base of the bulb and clean its mating contact in the lamp assembly.

TTR 225 DSK (PART# 12-1013)

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PARTS LIST CHECKOFF SHEET □ DSK Headlight – Blue– Includes the following:

□ Headlight Shell (60-1109) Headlight Lens (60-0002) & Graphic (40-0074)

□ Wired Running Light (60-4006) □ 55/60W Bulb (13-0014)

□ Horn (12-2001) □ Flasher (60-3008)

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

□ Adjustable Rubber Strap 4- (60807)

□ Front Harness E w/ key switch (12-9028)

Individual Parts:

□ AC DOT Taillight (30” Wires w/ 3-Pin Connector) (60-2012)

□ 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:

Mechanical Brakeswitch

□ (12-0106)

□ Misc. Hardware 1 Zip-tie Bundle 2 4x16mm Phillips-head bolts, 4mm washers, 4mm nuts 1 6x16mm Reduced Flange Head Bolt, 6x18 Washer, 6mm Nyloc Nut

3 Male & Female Connectors

1 TTR 225 Brake Switch Bracket

□ 1 TTR 225 DSK (Part # 12-1013) Installation Manual

□ CHECKED BY:________________________________