yamaha, yz450f efi dual sport kit 2010-2013

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Yamaha, YZ450F EFI Dual Sport Kit 2010-2013

PN: 12-1056-WT

Installation Manual

Baja Designs • 185 Bosstick Blvd. • San Marcos • CA • 92069

Phone 760.560.2252 • Fax 760.560.0383 • [email protected]

www.bajadesigns.com

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LIMITED LIFETIME WARRANTY

Baja Designs proudly offers a LIFETIME WARRANTY against manufacturer’s defect on all of the products that we manufacture.

These are comprehensive warranties; other than the exclusions below – you’re covered. If your LED or HID bulb burns out, you’re covered. Additionally, cutting off our connector or changing your lenses does not automatically void your warranty.

Exclusions: Installation errors, abuse, misuse or crash damage. You must be the original owner of the product and be able to supply proof of purchase.

NiCad DSK Batteries: carry a 90 day warranty Dual Sport Kit Switches: carry a 1 year 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 pay the freight if your product is less than 90 days old, otherwise defective products must be returned to Baja Designs, Inc., freight prepaid. At our option, we will repair or replace items in question and return them at no charge. If the identical product is no longer available we will replace with a similar product of equal value. Baja Designs Inc. will not be responsible for any indirect or consequential damages in connection with defective merchandise.

Indemnification:

Buyer hereby acknowledges off roading, racing and driving at night are dangerous activities 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,

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delivery, or use of purchased products and/or supplies exceed the purchase price of the products and/or supplies.

Note: YZ450F electrical systems are capable of powering lights however their capacitors are not strong enough to run larger than a (provided) 35W headlight. For off-road, low RPM riding situations, Baja Designs recommends running the dual-sport kit in the “parking light” (headlight off) switch position to avoid capacitor discharge.

Step 1: Remove the seat, fuel tank, side panels, and front number plate. Step 2: Taillight Installation: Mount the taillight to the underside of the fender as shown in Photos 1 using the provided countersunk mounting hardware. The front edge of the black taillight plastic should contact the sub frame and the LED cluster should not protrude out beyond the edge of the fender. Route the wires forward along the left side of the sub frame using zip-ties. Step 3: Rear Turn Signal Installation: Bolt the provided turn signals into the provided taillight housing. Step 4: Hydraulic Brake Switch Installation 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.

Photo 1

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Remove the rear master cylinder guard. Remove the bolt holding the brake fluid reservoir to provide access to the master cylinder. Loosen the banjo bolt securing the rear brake line to the master cylinder. Typically, this bolt will be very tight and loosening it will bend the support hanger for the master cylinder if not supported. Brace the master cylinder with a wrench or lever as shown in Photo 1. Remove the banjo bolt and replace with the hydraulic switch. Make sure to install the copper crush washer from the stock bolt under the switch. Torque the switch assembly to 25 lbf-ft. Run the brake switch wires up the rear subframe triangle to the area behind the airbox cross-member. Bleeding the Brakes: (Do not begin this process unless you have a fresh can of brake fluid) Re-install the brake fluid reservoir and remove the lid. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 9 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system - The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY - ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly. Step 5: 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.

Banjo Bolt

Brace Master cylinder here

Photo 1

Hydraulic Brake Switch

Copper Crush Washer

Brake Fluid Reservoir

Photo 2

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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.

Step 6: 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 in contact with any part of the chassis. The stock key switch MUST BE USED, it needs to remain for the bike’s starter to work***

Step 7: 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. 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. Step 8: Rear Wiring Harness Installation and 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 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.

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

The rear connections are completed. Secure your wiring with zip-ties. Step 9: Kill Wire Connections: Note: This step is optional. Skip this step if you do not wish to have the kill feature on the provided switch panel functional.

Locate the kill switch on the bike trace the wires to a point where you feel comfortable at tapping into.

Locate the separate 2-wire extension (yellow & black) provided with the dual sport kit.

Ground the black wire to the ground on the on/off switch ground wire (Typically Black OR Brown)

Attach the yellow wire to the positive side of the on/off switch (Typically Brighter colored)

Route the other end of the extension (both female) to the area behind the headlight. Plug in the yellow wire to the white wire and the black one into the blue wire.

Step 10: EFI Harness installation

Disconnect the capacitor from the mount on the motor.

Disconnect the capacitor from the male connecter with female pins.

Locate the T-Harness in the kit that has 3 connectors on it 2 that will be extensions for the capacitor. Then bypass the capacitor with the extension.

Then put the capacitor back into the stock location.

Route the wiring harness up through the frame where the stock wiring harness is.

Take off the left side panel then route this harness to the outside of the frame and back into the air-box.

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Step 11: 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 light green 4 pin connector to the key switch assembly. 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.

Headlight Mounting: When mounting the headlight to the fork tubes, first attach the four rubber pads to the metal brackets. Hold the headlight assembly up to the fork tubes and slide the hose clamps through so the head of the clamp is on the outside of the bracket.

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Tighten the clamps just enough to hold the headlight onto the forks. Make sure the headlight is in the desired location and tighten the clamps. If desired, you may cut off any excess strap that extends out from the bolt head of the clamp.

The headlight beam can be adjusted up or down by loosening the top bolts and pushing up or down. Likewise, the bottom bolts can be adjusted for height or clearance.

If you don’t like the look of the brackets on the outside, you can reverse them and put the heads of the clamps on the inside of the brackets. Turn the bars from side to side to make sure the clamps do not hit the tank or any other wiring.

Connect the white plastic connectors from the headlight and harness.

The following connections are pre-attached before shipping;

Flasher: The orange with white tracer, red & green wire 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 w/yellow tracer and black wire pair attach to the two wires from the right turn signal. The brown w/white tracer and black wire pair attach to the two wires from the left turn signal. Note: 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.

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ACEWELL: All kits now come prewired with a triangular female 3-pin plug which allows you to easily power an Acewell 1550T speedometer/tachometer unit. Contact Baja Designs at 760-560-BAJA for more info. To see the full line of Acewell speedometers visit www.BajaDesigns.com If you’d like to run another Acewell speedometer, GPS Unit or other speedometer, you can cut the connector and splice the corresponding wires based on the chart below: BLACK – GROUND BLUE- SWITCHED HOT GREY – CONSTANT HOT The wiring is now completed. Proceed to the next section to check your work. 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” postion 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.

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Note: The Key Switch must be on for the bike to run or any lighting functions to operate. 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. Make sure all the silicone rubber connector boots and the connectors are pushed firmly together and no bare metal is exposed. Removing and reinstalling the kit: To remove the kit, simply unplug the connector that mates the middle harness to the rear harness and the connector that joins the battery leads to the rear harness. Remove the “dual sport rear fender” with the rear harness still attached to it and reinstall a stock fender (not supplied.) The middle harness stays on the bike. The front signals can unbolt and unplug individually.

TROUBLESHOOTING Nothing Happens When You Turn the Power Switch On.

Main fuse is blown. Check for bare wire or terminal shorting against the frame or another wire.

Multi-pin connector not properly connected.

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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The Turn Signals Won't Come On, or Won't Flash

Check the turn signal wire connections. Make sure you have connected the correct wires to the turn signals. Check

instructions. Battery voltage is low. If the battery voltage is low, the turn signals won't flash, or

will flash very slowly. Running the bike will cure this as well as charge the battery. If only one signal lights and does not flash, it means that the other signal is not

properly plugged in, or the bulb is burned out. 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 brake light switch can become somewhat sticky after repeated exposure to water, dirt and mud. You can take the switch apart by removing the rubber cap and can lube to inside liberally with dielectric.

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June 2015

Yamaha, YZ450F EFI Dual Sport Kit (PART# 12-1056-WT)

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

□ Headlight Shell (60-1106) Headlight Lens (60-0002) & Graphic (40-0074)

□ Wired Running Light (60-4006) □ 35W Bulb (13-0011)

Horn (12-2001) □ Flasher (60-3008)

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

4-Adjustable Tecate Mounts - (12-0015)

□ Front Harness E w/ Key Switch (12-9031)

□ Choose One Determined by year

Rear-EFI harness for capacitor (12-9056) 10-13

Individual Parts:

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□ LED Taillight (32” Wires w/ 3-Pin Connector) (60-0710)

□ 2 - Turn Signal w/ Nuts & Washers (18” Wires) (60-4185)

□ Switch Panel (12-9028)□ Electric Start Rear Wiring Harness (20100)

4-Hose Clamp #28 (20-1604)

Kill wire extension F (43-105)□ 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

4-Hose Clamp Sheathings (20-1605)

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□ Parts Bag – Includes the following:

Nissin Hydraulic Brakeswitch (12-0104)

□ F780 Brake Switch Bracket (22-640) Unbent

□ Misc. Hardware 1 Zip-tie Bundle 4 6x20 Countersunk Bolts, Bezels, 6x18 Washers, 6mm Nuts 1 Brake Bleed Tubing 3 Male & Female Connector 1 6x12 flanged bolt 6x18mm

washer 6mm nut

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□ Electric Start Mid Wiring Harness (22700)

□ 1 YZ450F (Part# 12-1056) Installation Manual □ CHECKED BY:________________________________

yamaha, yz450f efi dual sport kit 2010-2013

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