Electrosport Yamaha WR/YZ Dakar Kit
Contents
1. Female Connector a Connect one of the BLACK brake switch male into eS Orange Female Connector the BROWN female connector and the second P BLACK brake switch male into the dual VIOLET Black Female Connector connector Note Be sure to carefully and fully seat the connectors BLACK TURN SIGNAL GROUND into position Double check the connections BLACK TURN SIGNAL GROUND BLACK cE BROWN TAIL LIGHT GROUND Secure Cable Ties Use a few cable ties along the sub frame to hold GRAY aE Sosa WHITE TAIL LIGHT the harness into position Make sure that you secure the harness to frame areas that will not ORANGE SHE BLACK RIGHT TURN SIGNAL bind or crimp the harness PINK TEFFGH_ cp BLACK LEFT TURN SIGNAL BROWN GREE BLACK BRAKE SWITCH VIOLET BLACK BRAKE SWITCH WHITE GREEN BRAKE LIGHT Hed J YAMAHA YZ WR INSTALLATION DUAL SPORT KITS i HEADLIGHT WIRING Main Wiring Harness Connection Access the Dakar wiring located behind the headlight by loosening two lower screws and remove two top inboard screws This is required in order to provide enough freeplay to tilt the headlight forward for harness connections Please refer to headlight adjustment for more information From the main wiring harness connect the VIOLET pai and BROWN female connectors into the front brake Main Wiring Horn wiring light switch male connectors Harness connection plugs Pluoci POTOM ia2. and along handle bar behind Dakar headlight unit and in through frame cable guide Secure switch wiring to handlebars with one cable tie For more information please refer to the cable routing diagram on page 2 Cable Tie Hed i M DUAL SPORT KITS V YAMAHA YZ WR INSTALLATION BRAKE LIGHT SWITCHES Check Thread Pitch Before sa Installing O WARNING Check the thread pitch on your banjo bolts Make sure the thread pitch on your stock banjo bolts match the replacement versions provided in the kit More than likley they will match Some manufactures have changed the stock design requirement which is why it necessary to check If your parts do not match up stop the installation and give us a call We ll send replacement parts to you Master Brake Light Cylinder Cable KESS ILE 2 AUCH oe Q Ge O Banjo Bolt Soft Washers Banjo Bolt Banjo Bolt 4 Brake Light oe o Fastening Screw Front Brake Light WARNING Bleed front and rear brakes according to instructions provided in your owners or service manual This must be performed in order for proper brake operation Failure to do so may result in brake failure Step 1 Place a drop cloth or rag under the front brake and bike to catch any fluids Loosen and retain banjo bolt on master cylinder Step 2 Insert brake light switch into position and fasten with banjo bolt on top of soft washer hydrauli
3. move around or touch the grounding tab Step 4 On the connector block of the 12 inch wiring sleeve you need to snip ss the pink wire about an inch behind the connector block You then JET need to solder a three inch long piece of pink wire to this end Then a p crimp the female bullet terminal with insulating sleeve to the end of Step 2 4 this wire NL Step 5 Where the original pink wire attached to the connector block strip and solder a twelve inch extension of black wire and attach a round grounding terminal to this end Female Soldering Bare Wire Heat Shrink PINK Wire with slack pulled out Female Bullet Soldering The Female Bullet Ground Terminal Step 4 Soldered Piece 10 Hed J YAMAHA YZ WR INSTALLATION DUAL SPORT KITS i HEADLIGHT ANGLE ADJUSTMENT Attaching The Headlight After the wiring harness has been securely fastened and the complete system has been tested you can now tilt the top of the headlight into the riding position and fasten the two inboard screws A as shown Complete the assembly by tightening the lower two screws B Accessing the wiring behind the headlight When accessing the Dakar wiring located behind the headlight you must loosen the two lower screws B and remove the two top screws A This is required in order to provide enough clearance while tilting the headlight forward BEFORE RIDING YOUR BIKE Ignition Key The
4. Dakar Dual Sport Kit features a security key designed for theft prevention and unauthorized operation of the motorcycle To start the motorcycle rotate the key to the ON position as shown IMPORTANT Do not leave the headlight on without the engine running It could cause damage to the battery We also suggest turning up the idle speed slightly to increase system voltage while the engine is at idle The key is designed only as a means to disable operation of the motorcycle Use the turn signal kill switch to shut the motorcycle off Leaving the key in the ON position will drain the battery so be sure to turn the switch to the OFF position while leaving the bike unattended Now start your bike up and go show your friends Key OFF Position Key ON Position 11 a DMV DuaL SPORT REGISTRATION OVERVIEW DUAL SPORT KITS Overview Vehicle registration policies in most states typically allow conversion of an off road only title into a street title or in some states a designated Dual Registration To register a dirt bike for street use it must be equipped with the necessary lighting and other equipment required by your state s vehicle code Every state requires what is called The Federal Minimum Requirement which consists of e Headlight with a high and low beam e Headlight indicator light visible to the operator to show when the high beam is operating e Horn Some states mandate an electric horn e Battery powered taillight
5. Hi i Li aa J f U si Mana 7 i iy dine gt 2 k ju OB 4 J s be ii YAMAHA WR YZ DUAL SPORT Kit INSTALLATION YAMAHA YZ WR INSTALLATION DUAL SPORT KITS Kit CONTENTS Inspect Your Kit Your kit will include the following items A WR YZ Installation Instructions Read through the entire instruction manual before starting B Dakar Headlight Assembly C Handlebar Turn Switch D Horn E Tail Light and Mounting Screws F Universal Hardware Bag Contents Turn Signals 2 Brake Light Switches 2 Cable Ties Wiring Diagram Label Round Plastic Signal Alignment Wedges G Main Wiring Harness Note Ignition Keys Zip Tied to Harness H Mounting Kit Hardware Bag Triple Clamp Mounting Brackets Kit Specific Pieces Note Please take a moment to become familiar with the contents of the kit Due to slight variances between motorcycle models there may be differences in the instruction manual drawings and the actual parts The basic installation procedure remains the same Brake Light Switches YAMAHA YZ WR INSTALLATION DUAL SPORT KITS HEADLIGHT SuB ASSEMBLY Horn Mounting Hole Getting Started Remove and retain four 4 retaining screws holding the headlight numberplate to the Dakar unit Then unplug the main wiring harness turn switch wiring harness headlight and horn wiring connectors from the Dakar unit Attach The Horn The horn may aread be installed on your kit if not t
6. Up gt O O Step 4 YAMAHA YZ WR INSTALLATION WR Mopbe ts Use a MoDIFIED WR STATOR Step 1 The grounding wire of the lighting coil must be un soldered from the ground and soldering tab This is easily done by placing a screw driver gently underneath the copper ground of the lighting coil doing so gives some leverage to the wire so that a soldering iron can easily free up the original soldered wire Then while applying a heated soldering gun carefully lift the copper grounding wire out of the soldering tab Step 2 On the backside of the stator there is a backing plate that secures the wire harness which goes to the stator Remove and retain both screws and backing plate Step 5 Slide a piece of heat shrink over the wire at the connector end before soldering Then add a female bullet connector securely crimping the connection Now add a dab of solder on each bare wire then solder to two pieces together Complete by apply heat to the heat shrink wrap Female Bullet Connector Soldering Step 5 Bare Wire Zhuo Shrink 2 Step 6 New Yellow Wire added SX Free Ground Wire Ez Step 6 After the female bullet connector has been added and the wire has been pushed through the grommet you can route the new yellow wire up behind the stator where the bracket has been taken off into position near the loose copper ground wire previously freed Solder together the
7. and brake light which must operate for 20 minutes on battery power alone e Rear view mirror e Turn signals for motorcycles manufactured after 1 1 73 Most States e Some states require speedometers and odometer s e Tires should be DOT approved e Lights should be DOT approved e Fuel tank should be DOT approved Even though the Federal Motor Vehicle Safety Standard specifies steel gas tanks for street motorcycles most states will not enforce this for converted dirt bikes Registration procedures vary from state to state but typically involve e Signing two Statement of facts certifying that your bike meets state federal standards e Bringing the bike to the DMV or AAA Insurance Office for an inspection for proper lighting Once the paper work and inspection are complete the final step is to exchange your off road title for a street title Exchanging your title Most states have a Dual Registration Form You should be able to download this form from your states DMV over the internet or filling it out at your DMV office Then pay the transfer fee and obtain your registration put the plate on your bike and go show your friends 12 TROUBLESHOOTING DUAL SPORT KITS Nothing Happens When You Turn the Power Switch On Possible Causes e Fuse is blown Check for bare wire or terminal shorting against the frame or another wire e Multi pin connector not properly connected to the circuit board Poor battery connection Make su
8. c line and second soft washer Securely fasten banjo bolt without stripping Step 3 Route the front brake light switch wiring along the lower portion of the handlebar towards the center of the triple clamps Fasten wiring to the handlebar with a cable tie Brake Pedal Light Step 1 Place a drop cloth or rag under the rear brake and bike to catch any brake fluid Remove the screws and guard providing access to the rear brake master cylinder You must temporarily reinstall the screws that attach the master cylinder to the frame to prevent damage to the master cylinder or Banjo bolt threads After the master cylinder is secure carefully remove the existing banjo bolt Remove and retain the mounting screws Note Some bikes allow access to the master cylinder without removing a cover or guard Step 2 Insert brake light switch into position and fasten with banjo bolt on top of soft washer hydraulic line and second soft washer Securely fasten banjo bolt without stripping Reinstall guard with screws Step 3 Route the rear brake light switch wiring up the sub frame spar a following behind the airbox up towards the back of the frame The wiring should meet up next to the main wiring harness tail light and turn signal connection point YAMAHA YZ WR INSTALLATION DUAL SPORT KITS TAILLIGHT AND TURN SIGNALS It is suggested that you read through these instructions completely prior to starting the installation Remove Exis
9. he horn just slide the blue connector sleeve back and connect the charger up to the exposed terminal You do not need to disconnect the horn Turn key switch to ON Position e flasher relay is bad Replace with new one Blinkers don t work at idle or flash intermittently Possible Causes e Battery is not charged Charge battery using a standard battery charger Connect the black negative lead from the charger to a good frame ground and connect the red positive lead from the charger to the blue lead that connects to the horn just slide the blue connector sleeve back and connect the charger up to the exposed terminal You do not need to disconnect the horn Turn key switch to ON Position increase the idle speed a little Dual sport setups work a lot better is the idle speed is a bit on the high side This is due to the design of most of the lighting charging coils which really start putting out power at around 1200 rpm 14 TROUBLESHOOTING DUAL SPORT KITS Horn doesn t work Possible Causes e Battery is not charged Charge battery using a standard battery charger Connect the black negative lead from the charger to a good frame ground and connect the red positive lead from the charger to the blue lead that connects to the horn just slide the blue connector sleeve back and connect the charger up to the exposed terminal You do not need to disconnect the horn Turn key switch to ON Positio
10. he horn has a nut with a washer screwed on the back Remove and retain the nut and washer Locate the horn s threaded stud on the outside of the Dakar unit and into the horn mounting hole in the Dakar unit Fasten with previouslt removed washer and nut Be sure to tighten securely without stripping Mounting Brackets Attach headlight mounting brackets A with two screws B on each side Tighten screws securely into the Dakar headlight unit C without stripping Note Bracket shown in illustration may differ from pieces in your kit However the installation will remain the same Installing The Dakar Headlight Unit Remove and retain existing top triple clamp bolts E Carefully slide brackets into position and fasten with existing bolts as shown WARNING Torque triple clamp bolts as specified in your service manual Note Headlight assembly omitted from illustration for installation clarity YAMAHA YZ WR INSTALLATION DUAL SPORT KITS TURN SWITCH INSTALLATION Remove Existing Kill Switch Step 1 Using a small phillips head screwdriver loosen the locking screw B on the kill switch C Remove any cable ties and unplug kill Switch from existing wiring Step 2 Loosen clutch cable perch D and move inboard about 1 2 inch Install Turn Switch Step 1 Open and wrap the new turn switch E around handlebar and securely fasten with two screws F as shown Step 2 Route turn switch wiring down
11. hrough the right side hole and then the turn signal wiring J Secure turn signal with supplied alignment wedges washer and nut H Attach second turn signal following same procedure and complete by reinstalling rear fender on bike WR Installation Important Note Tail light on WR omitted for clarity Note There may be differences in the instruction manual drawings and the actual parts Hed J YAMAHA YZ WR INSTALLATION DUAL SPORT KITS i TAILLIGHT AND TURN SIGNAL WIRING CONNECTION Wiring Harness Location Feed the main wiring harness through the Violet Female Connector White Green Male Connector frame cable loop behind the triple clamps Brake Switch For more information please refer to cable Male Black Gray Female Connector routing diagram For reference stick the wiring iaht fon Slana connection decal on the rear fender below where U SIMS the seat will cover it up Taillight Connection Connect the WHITE tail light male to the GRAY female connector Connect the BROWN tail light male ground to the BLACK female connector as shown Turn Signal Connections Connect both BLACK tail turn signal grounds into the dual BLACK female ground connector Connect the ORANGE female into the BLACK male right turn signal connector and the PINK female into the BLACK male left turn signal connector Brown Female Connector es Pink Female Connector Brake Switch Connection Black
12. ht sid i into circuit board ug in main wiring harness righ side connector Front Brake Light Be sure to fully seat the connection You will hear the MEA ie VIOLET and BROWN connector click into position on both the top and bottom Horn Connection From the turn switch wiring harness connect the PINK and BLUE leads into the horn spade connectors Turn Switch Wiring Connection Plug in main turn switch wiring harness connector into the right side block connector on the Dakar unit Be sure to fully seat the connectors You will hear the connector snap together on both top and bottom pieces when they are correctly fastened Headlight Cable Connector Main Wiring Harness Connection Plug in main Main wiring harness connector into the left side block connector on the Dakar unit Be sure to fully seat the connection You will hear the connector snap together on both top and bottom pieces when they are correctly fastened Turn Switch Wiring Harness YAMAHA YZ WR INSTALLATION DUAL SPORT KITS WIRING HARNESS CONNECTION Dakar Wiring Harness Dakar BLACK Ring Terminal Ground Connection K Switch Connection Male BLACK WHITE Connects To Existing Female Kill Switch Connection Dakar Wiring Pa Harness LACA O a Dakar Stator YELLOW Existing Stator Connection Male Connections YELLOW and YELLOW or PINK Wires Dakar Wiring Harness Ground Connection WR OWNERS IMPORTANT NOTE You will need t
13. n e Adjust small set screw on the back side of the horn Turn it both ways until you get a nice loud honk Lost key while riding Possible Causes The Dakar setup will perform fine but you ll have to top up the battery regularly weekly to prevent it from going flat Call ElectroSport for a replacement Kill button does not work Possible Causes e Ensure that the black white wire of the wiring harness is plugged in correctly e If the kill button does not work but turning the key switch does kill the engine you have a dirty handlebar switch Spray inside it with WD40 Technical Support Contact Information ElectroS port Industries 3803 Oceanic Dr Ste 201 Oceanside CA 92056 PH 760 842 8300 9 5 M F PST WEB www electrosport com email Info electrosport com 15
14. n the bulb could have gone out Check the connections in the bulb holder as well water could oxidize the contacts preventing the bulb from coming on Check the connections especially the ground under the seat You ll find a gray wire taillight positive a black wire taillight and brakelight ground and a violet wire purple brake light positive Check these connections carefully 13 id TROUBLESHOOTING DUAL SPORT KITS Brake light stays on Possible Causes e unplug the brake light switches one by one If one of the switches is bad it will close its contacts and leave the brake light on The brake light switch that makes the brake light turn off as soon as you unplug it is bad Brake light does not work Possible Causes Check the bulb Due to vibration the bulb could have gone out Check the connections in the bulb holder as well water could oxidize the contacts preventing the bulb from coming on Check the connections especially the ground under the seat You ll find a gray wire taillight positive a black wire taillight and brakelight ground and a violet wire purple brake light positive Check these connections carefully Blinkers don t work Possible Causes e Battery is not charged Charge battery using a standard battery charger Connect the black negative lead from the charger to a good frame ground and connect the red positive lead from the charger to the blue lead that connects to t
15. o modify your existing a stator using the detailed modification instructions Connect the main wiring harness BLACK ground ring terminal to the 9 existing ignition coil ground location YZ OWNERS IMPORTANT NOTE s P The YZ model reguires using a modified WR stator and flywheel Please Dakar Wiring Kill Switch Connection see the detailed jeo Y Connect the Dakar wiring harness BLACK WHITE male kill switch wire to the existing kill switch female connector NOTE Your motorcycle CDI kill switch should be a black and white wire If not please refer to your owners manual Dakar Wiring Stator Connection Step 1 Connect both YELLOW male connectors from the Dakar wiring harness into the existing stator power connection DUAL SPORT KITS Copper Grounding Wire and soldering tab Heated up solder frees the copper ground wire View in circle enlarged Backing Plate Step 2 ae Existing Wiring Existing wiring coming through grommet Backing Plate Screws New Female Bullet Connector Step 3 From the plug end of the wiring harness you will need to add a second female bullet connector Slice the protective wrapping around the wiring and then add the new wire all the way up to the grommet New yellow wire added Step 3 Step 4 The grommet require opening up one of the holes where the new wire will slide through This can be done carefully using a pen knife Existing wires Slot Opened
16. re the connectors are fully seated e Battery is flat Measure voltage with voltmeter or connect a 12 volt light across it A fully charged battery will measure between 12 9 and 13 2 volts e Poor connection at the blue wire junction above the shock Headlight does not work on high beam or low beam Possible Causes Check the bulb Usually one of the bulb filaments is bad so replacing it will fix the problem Make sure you replace the bulb with the exact same wattage The handlebar switch is dirty inside Clean it out with some WD40 Headlight is dim at idle Possible Causes Increase the idle speed a little Dual sport setups work a lot better is the idle speed is a bit on the high side This is due to the design of most of the lighting charging coils which really start putting out power at around 1200 rpm e Battery is not charged Charge battery using a standard battery charger Connect the black negative lead from the charger to a good frame ground and connect the red positive lead from the charger to the blue lead that connects to the horn just slide the blue connector sleeve back and connect the charger up to the exposed terminal You do not need to disconnect the horn Turn key switch to ON Position Check bulb wattage Certain kits come with a lower wattage bulb than a standard H4 bulb ElectroSport has all bulbs in stock Taillight does not work Possible Causes Check the bulb Due to vibratio
17. ting Parts Remove your existing seat front number plate radiator covers fuel tank side number plates and rear fender Please refer to your owners manual for detailed dis assembly instructions for each item Taillight Assembly Place the rear fender A upside down on a clean work surface and position the rear tail light B on the inside of the fender Note the tail light should rest slightly under the rear edge of the fender Using the rear taillight s four mounting holes C as guides trace around each hole with a felt tip marker on the underside of the fender creating drill hole locations Remove the tail light and drill 1 4 inch holes Reposition the tail light and fasten with supplied screws washers and nuts D as shown Turn Signal Mounting Step 1 Position the rear turn signals by visually lining up the signals G behind the rear seat when its attached to the sub frame Care should be observed to insure signals do not interfere with the rear silencer The signals must mount free and clear of exhaust heat in order to prevent damage to the signal Once you have found a suitable location for the signal mounting hole E mark and drill one 3 8 inch hole through each side Step 2 Drill a second hole F on each fender side allowing the signal wiring to pass through underneath the rear seat Note On some bikes signal wiring holes are already available Step 3 Feed the tail light wiring 1 t
18. two pieces which creating an additional lighting coil Complete the modification by wrapping the wires with protective tape behind the stator where the bracket attaches Then reinstall the bracket and screws previously removed Note be sure to use a locking compound on all screw threads Note This new yellow wire you have added will connect to the Dakar wiring harness YAMAHA YZ WR INSTALLATION DUAL SPORT KITS YZ Mopbe ts Use A MoDiFiED WR STATOR AND FLYWHEEL Step 1 G The grounding wire of the lighting coil must be unsoldered from B the ground This is easily done by placing a screw driver gently Na underneath the copper ground of the lighting coil doing so gives sos some leverage to the wire so that a soldering iron can easily free up ug Grounding this soldered original wire Then while applying a heated soldering gun carefully lift the copper grounding wire out of the soldering tab Wire and soldering tab Step 2 Tilt the stator on its side and you will see where the PINK wire attaches to the coil Cut the pink wire as close to the coil as possible Then you need to strip the end that has been cut free by about 1 4 inch and solder it to the end of the copper lighting coil wire you previously freed Then pull the pink wire out taking up the extra slack from the black block connector side Step 1 Step 3 Put a dab of epoxy on the soldered connection This is done so that PINK Wire the connection does not
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