Baja Designs KDX200, KDX220 User Manual

KDX200220 Dual Sport Kit

Installation

Manual

185 Bosstick Blvd. ♦ San Marcos ♦

California ♦ 92069

Phone [phone] ♦ Fax (760) 560-

0383

E-Mail: [e-mail]

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Internet: http://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 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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‘95-on Kawasaki KDX 200/220 Installation Manual

1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!)

2. Remove the seat, side panels, radiator shrouds, and gas tank.

3. Unplug the taillight from the stock wiring harness, remove the taillight lens, and
remove the taillight socket and wiring.

If you are color blind or even think you might be a little color blind, now is the time to
get someone to assist you. Successful installation of the kit requires good color
recognition. You want to go riding this weekend, don't you?

4. Unplug and remove the head light on/off switch from the wiring harness. Detach the
headlight from its wiring at the bulb socket and remove headlight. The headlight wiring
unplugs underneath the tank area. Unplug the red and yellow leads of this wiring,
remove the ground attachment from the ignition coil and remove this wiring.

Figure 1

Unplug headlight and kill
button wirin

here.

Run Gray Multi­conductor cable
as shown here.

Unplug Lighting Switch

Disconnect
headlight
and kill
button

rounds here

Stator Wirin

5. Remove the kill switch. Unplug the black/white wire from the region below the tank
and remove the its ground from the ignition coil. Make sure to reinstall the coil and the
remaining ground wire.

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6. Locate the AC voltage
regulator found mounted to the

Photo 1

CDI Unit

Remove
AC Voltage
Re

ulator

enough to run the full street lighting system. The stator will have to be rewound and the
ground floated for the kit to work properly. If you have not already done so, remove the
stator plate by removing the shifter, left mag cover, flywheel, and the two screws which
secure the stator plate. Make note of the timing marks on the stator plate and how they
are referenced to the timing index on the case so that you can reinstall the stator plate in
the same position. You will need a flywheel puller to remove the flywheel.

Once the stator has been rewound, reinstall and run its wiring back up to the front right
corner of the airbox.

8. Taillight Installation: Install the Acerbis DOT taillight over the empty well left in
the stock fender using the two small sheet metal
screws and 6 x 16 mm bolt found in the parts
bag. Position the Acerbis taillight so that the top
two mounting holes line up with the top edge of
original taillight well as shown in Photo 2.
Transfer the hole locations for the top mounting

Drill 1/16”

Photo 2

Drill 1/4”

holes onto the fender with a felt pen or snap
punch. Drill two 1/16 inch holes for the top
mounts. Attach the taillight with the two small
Phillips head sheet metal screws in the parts bag.
Once in place, drill the bottom mounting hole
using a 1/4” drill. When installing the lower
mounting bolt, make sure to install the 6 x 16
mm bolt from the bottom up to minimize the
opportunity for the tire to grab it. Run the
taillight wires along the left frame rail using the
stock wire clamps to support it. Bring the ends
of the taillight leads up on top of the rear fender
to the area that is below the seat.

top of the airbox lid. It is a
silver finned aluminum box
measuring approximately 1­1/4" x 2" (Photo 1) with two
wires exiting it . Unplug the
regulator from the wiring
harness and remove regulator.

7. The stock stator on the KDX
is good for about 40 watts of
lighting output. This is not

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Photo 3

7/16”

diameter bolt and nut to sandwich
two fender washers on the inside and
outside of the fender. Carefully heat
the inside of the fender with a heat
gun until you can pull the bolt down
to horizontal. Reinstall turn signals.

Run the left turn signal wires along
with the taillight wiring forward
along the left frame rail to the area
just behind the airbox and above the
fender. Run the right turn signal
wires forward along the right frame
rail, and up to the same location
behind the airbox.

9. Rear Turn Signal Installation:
Turn signal mounting requires that
you drill a 15/32 inch hole in either
side of the rear fender near where it
meets the side panels. You can
achieve a clean, durable installation
using this mounting location..
Mount the rear turn signals by
drilling a 3/8" hole in the rear

3/8”

fender in the location shown in
Photo 3, three eighths of an inch
back from the front edge. If you

desire the turn signals to be
completely level, use a 3/8 inch

Photo 4 - Left Side
Turn Si

gnal Mounting

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