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Yamaha TTR225

Dual Sport Kit Installation Instructions

185 Bosstick Blvd. San Marcos California 92069

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

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info@bajadesigns.com

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Warranty: Baja Designs manufactures its own products as well as resellsproducts manufactured by others. Baja Designs makes no express orimplied warranties on products not manufactured by Baja Designsincluding without limitation any warranties or merchantability and fitnessfor a particular purpose. We will however, pass on all warranties made bythe manufacturer, who has sole responsibility for performing suchwarranties. Baja Designs will repair or replace any item manufactured byus that we judge to be defective in workmanship or material within 30 daysof shipment. We will not be responsible for any indirect or consequentialdamages in connection with defective merchandise. Products used inracing, competition or damaged by crash, abuse, or misuse are not

warrantable.

Indemnification: Buyer hereby acknowledges motorcycle riding is a dangerous sportand that the products and/or supplies purchased from Baja Designs areused 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 liablefor consequential damages, nor shall seller's liability on any claim fordamages arising out of or connected with the sale, delivery, or use ofpurchased products and/or supplies exceed the purchase price of theproducts and/or supplies.

Dual Sport Kit: Installation of a Baja Designs Dual Sport kit by itself does not makean off-road motorcycle street legal. Each state has different equipmentrequirements for street legal motorcycles, including but not limited to suchitems as DOT approved tires, left and right side mirrors, speedometers,quiet exhaust, chain guards, and side reflectors. Contact your statesdepartment of motor vehicles or highway patrol for acomprehensive list ofequipment that is required for street motorcycles before riding your bike onthe street.

Street Riding: Riding a motorcycle on the street is very different than off roadriding and requires special skills not learned off-road. Most states require

an additional license beyond an automobile drivers license to operate amotorcycle on the street. Make sure to have the proper licensing andskills before riding your bike on the street. Baja Designs recommendscontacting the Motorcycle Safety Foundation (800 446-9227) for a ridercourse 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 two3/16 mounting holes as shown in Photo 1. The position of the holes isdetermined by carefully positioning the taillight assembly over the opening andtransferring the top mounting hole locations to the fender. You want to makesure the holes are as close to the edge of the well as possible and just miss theplastic molding when drilling through the fender. Note location of holes relative tothe opening it the Photo 1. Drill a 3/8 hole at the left side of the well for wirerouting. Using the 4 mm screws provided, temporarily install the taillight over the

opening so that you can determine the location for drilling the bottom licenseplate mount. Drill the license plate mount hole to 1/4 and mount the taillightassembly over the well, running the wires through the routing hole and along theleft seat frame rail. Make sure to install the 6x16 mm fastener for the licensemount 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 wirerouting

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Photo 2

3. Turn Signal Installation: The TTR 225 hasfactory turn signal mounts built in. Thesemounts must be drilled out (7/16) as shown inPhotos 2 & 3. Install the turn signals to thesemounts and run the wires forward along theleft and right frame rails.

Photo 3

4. Brake Light Switch Installation: Drill a 1/8hole in the brake lever as shown in Photo 4.The brake light switch bracket mounts under

the right side case mounting just above theswingarm pivot. We will adjust the switch in alater step.

Photo 4

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7. Rear Wiring Harness Installation & Connections:Make sure the 3-positionpower switch on the switch panel is in its lowest off position before making thefollowing connections.

Locate the rear wiring harness provided with the kit. It has a white plastic6-pin connector with several sheathed power leads extending from it.

Attach the 6-pin connector from the rear harness to its correspondingmate from the middle wiring harness.

Attach the ring terminal from the fused lead to the positive side of thebattery.

Attach the remaining black (un-fused) ring terminal to the negative side ofthe battery

Attach the 3-pin plastic connector from the rear wiring harness to itscorresponding mate from the taillight.

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

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

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

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

8. Front Wiring Connections & Headlight Installation:

Attach the black multi-pin connector from the headlight to itscorresponding mate from the switch panel assembly.

Attach the white multi-pin connector from the headlight to itscorresponding mate from the rear wiring harness (gray cable.)

Attach the headlight to the fork tubes. Turn the steering from side toside to verify that the wiring does not bind or get caught in thesteering stops.

The following connection have been made prior to shipping:

Turn Signals: The green and black wire pair attaches to the right turn signal. Thebrown and black wire pair attaches to the left turn signal.Horn: The red/purple & pink pair attach to the horn.Flasher: The red/green and orange wires attach to the terminals on the flasher labeledX & L respectively.Headlight and Running Light: The plastic H4 connector attaches to the three prongs

from the back of the headlight. The brown & green wires from the headlight connectorattach to the brown & green wires from the running light.

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

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System Checkout: The turn signal switch in this kit controls both the lighting andignition functions in one compact package. Using the lighting selector, push the switchto the second P position. The taillight should come on and the brakelight, turn signalsand horn should be operational. The third H switch position allows the high/low buttonto function.

Off

position

Parkinglight

position

Headlight on

position

Mainpower

switch

Turn signalswitch

Horn button

Engine

kill button

Highbeamindicator

light

If everything is working properly

congratulate yourself on a job welldone. If not, don't worry, it's notrocket science and we should beable to figure it out. All thecomponents were checked foroperation prior to being shipped toyou so something is probably notconnected correctly. See thetrouble-shooting list in a latersection.

Brake Light Switch Adjustment:Adjust the brake switch in its bracket so the brakelight comes on when the pedal is near the end of its throw. Do not adjust the switch toosensitive as this can lead to premature switch failure.

Wrapping It Up: It is important that all the wires be properly routed and secured. Makesure the wires do not pass over any sharp edges, are pulled overly tight, or can becrushed 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 thesilicone rubber connector boots and the connectors are pushed firmly together and nobare metal is exposed. Put on the seat, tank, and side panels, go down to your localDMV, 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 anotherwire. 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 terminallabeled "X". Check turn signal wire connections. Make sure you have connected the correct wires to the turn signals. Checkinstructions.

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 isalready on so their is no increase in light intensity when you activate the brake. Checkthe red and blue taillight connections. Short the two leads together at the brake switch. If the brakelight comes on, eitherthe 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 leadingto 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 surethey are not chaffing or binding so that they don't cause you a problem when you're outon the trail or on the road. A well routed, properly secured wiring system is key togetting long life and trouble free performance from your conversion kit. The light bulbstake a beating on a dirt bike, especially the rear taillights. The continuous vibration andimpact 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.

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