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




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.



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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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Photo 2
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.









Photo 3










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 4

















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5. Switch Panel Installation: 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 switch panel will remain unplugged.
These wires are not hot leads.

Photo 5
Install the switch panel assembly on the left
handlebar next to the grip as shown in Photo 5. 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.
Route the wires along the bottom of the handlebar
(so they cant get crushed by tie-downs) and over
the front of the upper triple-clamp.








6. 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 (doesnt 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. Well attach the connectors in later steps.


Middle Harness Photo 6




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7. 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.


8. 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 rear wiring harness (gray cable.)
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.

The following connection have been made prior to shipping:
Turn Signals: The green and black wire pair attaches to the right turn signal. The
brown 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 labeled
X & 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 connector
attach to the brown & green wires from the running light.


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

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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. The third H switch position allows the high/low button
to function.


Off
position
Parking
light
position
Headlight on
position
Main
power
switch
Turn signal
switch
Horn button
Engine
kill button
High
beam
indicator
light
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. All the
components were checked for
operation prior to being shipped to
you so something is probably not
connected correctly. See the
trouble-shooting list in a later
section.
















Brake Light Switch 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 means 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 their 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 the rear taillights. 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.
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