Baja Designs KLX 250, KLX 300 User Manual

KLX 250/300 Dual Sport Kit

Installation

Manual

185 Bosstick Blvd. ♦ San Marcos ♦

California ♦ 92069

Phone [phone] ♦ Fax [phone]

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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Kawasaki KLX 250/300 Dual Sport Kit

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 three bolts which secure it
from the underside of the fender and remove the taillight. Use the hardware (6x25mm flange
head bolts) provided to re-attach the fender to the subframe leaving the wire support in place.

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. 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.

manuals/kawasaki/klx300nw.doc

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Figure 1

Unplug headlight and kill
button wiring here.

Unplug Lighting Switch

Disconnect headlight and kill
button grounds here.

Stator Wiring

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.

6. Locate the AC voltage regulator found mounted to the frame just behind the engine on the left
hand side of the bike. It is a black finned aluminum box measuring approximately 1-1/4" x 2"
with two wires exiting it (Sorry no photo). Unplug the regulator from the wiring harness and
remove regulator.

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7. A slight modification to the wiring harness of the bike will have to be made in this step

A

"

Phot o 2

because we do not have a mate to the connector that
Kawasaki uses for the stator to voltage regulator
connection. Follow the stator wires up from the left side of
the engine as shown in Figure 1. Locate the two yellow
wires in the stator wiring that terminate in a black
connector . Unplug the connector, measure 7/8" back from
the connector and cut the two yellow wires (Photo 2).
Install two female bullet connectors from the parts bag on

Cut

these wires after stripping them back about 1/4". Take your
time and make sure to do a good job of crimping on these

7/ 8"

connectors as it is key to the system functioning properly.
You might want to practice on a scrap piece of wire first,
extra connectors have been provided for practice and

Con nect or

botched attempts. We do not recommend soldering as the
solder can embrittle the wire if it flows past the joint up the
wire.

irbox

Drill 3/ 16

8. Taillight Installation: Install the Acerbis DOT taillight
over the empty well left in the stock fender using the two 8-

32 x 3/4" bolts and 6 x 16 mm bolt found in the parts bag.
Drill a single 1/4 inch hole in the center of the fender 2
and 3/8" inches up from the bottom edge as shown in
Photo 3. Position the taillight so that the license plate
mount aligns with this hole and transfer the hole locations
for the top mounting holes onto the fender with a felt pen
or snap punch (Photo 3). Drill two 3/16 inch holes for the
top
mounts. When installing the bolts, make sure to install the

2-3/ 8"

Photo 3

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

Photo 4

stock wire clamps to support it.

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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

1-1/ 8

Fron t Edg e of fend er wher e it meet s sid e

Drill 3/ 8 " Dia.

side panels to mount the turn signals. You can actually
achieve a clean, durable installation using this mounting
location. See the color photograph, Photo 5 and Figure
2 for the mounting location.

1"

Figure 2: Left Side View of Fender,
Turn Signal M ount ing Locati on

Photo 5

To get the turn signals to be perfectly horizontal,
carefully heat the fender from the inside with a
heat gun. Install a 3/8 inch bolt through the hole
in the fender, using the large fender washers to
sandwich the fender on each side. Using a vise
grip, slowly pull down on the bolt while carefully
heating the plastic from the backside until the bolt
becomes level.

Run the left turn signal wires along with the

taillight wiring forward along the frame rails.
Pass the wires through the gap at the left hand side of the fender just above the fender mounting
bolt. Note that the wires of the right rear turn signal are shorter (5-1/2") than those of the left

turn signal.

Run the right hand turn signal wires similarly along the right frame rail to the area behind the
airbox.

10. Brake Light Switch Installation: The latest
KLX kit uses a hydraulic brake switch. This requires
replacing the rear master cylinder banjo bolt with a
specially made switch. Installing the switch requires
bleeding the rear brake. If you do not feel

competent bleeding your rear brake, please refer
this job to a qualified mechanic as failure to do it
correctly will make the brake inoperable.

Remove the banjo bolt from the rear brake master
cylinder, and replace with the hydraulic switch as
shown in Photo 6. Make sure to install the copper

crush washer from the stock bolt under the switch.

Torque the switch assembly to 25 lbf-ft.

Install
Hydraulic
Switch in place
of Banjo Bolt

Re-Install
Copper Crush
Washer

Photo 6

Run wires up
subframe

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