Baja Designs Dual Sport Kit

If I was going to DS my 450 I might think about keeping the stock reg/rectifier and running the lights off the AC side. It wouldn't be totally legal here in CA but you could probably get away with it. If a cop stops you (which I doubt would happen)just say "damn battery is dead again!" :) If I ended up replacing the regulator then I think I'd go full DC. Mixing loads on AC and DC can get a little tricky since many of the handlebar switches share common grounds with several of the functions (like the horn and the ignition kill for example).

That's how I'm setup now and have done 500miles with no problems. I have my headlight, taillight, lic. plate light and brake lt. on the AC side. TS's and horn on the DC. I figured if I needed an emergency light I could turn my flashers on. I do get the head light dimming when I hit the bake at low rpm, but when I get the LED taillight, it should solve that problem.

I'm thinking B.D. sells their kits state specific. This might explain running the headlight on the DC side for some kits. When I recieved my kit it had a copy of the Washington state requirements to be street legal. Having the head light on without the motor wasn't on there. So my kit runs the headlight off the AC side everything else off the DC. I will find the installation instructions and see if there any specifics that may be usefull here.

Later,

Lowedog

Actually to be legal in CA only the tail light has to be able to stay on without the engine running. Kind of dumb.

I called Ricky Stator a while back and he said that the DC side was just enough to run the charging circuit and ignition. Thats why I was draining my battery with the kit hooked up to the DC side and the light on for a period of time. According to the manual it looks like there is plenty of power on the stock AC side to run 80 or 90 watts of lighting without getting into trouble or a whole DC regulated kit.

This thread has been very educational. Thanks guys.

N7SLC,

Does DDIALOQUE have Hi and Low beam with that setup ?????

N7SLC,

Does DDIALOQUE have Hi and Low beam with that setup ?????

Yep! :)

Thanks man...

sounds like the way to go then!

Having Hi/Lo was a definite concern of mine.

That's great.

I believe the stock bulb is an H4 which has hi/lo beam already. The socket wasn't wired for it, but that was easy to remedy...He's in it less than a C-Note. :)

Quote from B.D. installation instructions.

"The WR 450 is unusual in that it has both a DC charging system and an AC lighting system. To install the DS kit without modifying the stock charging system, a headlight relay is used to to switch the headlight from high and low beams. Power for the headlight is picked up from the stock headlight connector."

Lowedog

Quote from B.D. installation instructions.

"The WR 450 is unusual in that it has both a DC charging system and an AC lighting system. To install the DS kit without modifying the stock charging system, a headlight relay is used to to switch the headlight from high and low beams. Power for the headlight is picked up from the stock headlight connector."

Lowedog

Interesting... :D

Why even use a relay? :excuseme:Just route the original power wire

for the headlamp through the bar-mounted hi/lo beam switch

then back to the headlamp.

BD is making this far more complicated than it needs to be.

Most of the dual-sport add-on switches can handle the

current load...

This method works great on ddialogue's bike. :)

I think they use a relay so that they can use an all-in-one handlebar switch (I.E. - headlights, taillight, turn signals, horn, kill switch). Most of those switches share a common ground and 12 volt supply so it is difficult to run both AC and DC circuits with them. Hence the relay. They power the relay with DC to control the AC going to the headlight.

I don't get it either. What’s up with this question? Run the existing AC to the handle bar sw. The sw has a wire for the hi and another for the lo. Connect these to the respective pins on the bulb socket and you are done. :)

Quote: I think they use a relay so that they can use an all-in-one handlebar switch (I.E. - headlights, taillight, turn signals, horn, kill switch). Most of those switches share a common ground and 12 volt supply so it is difficult to run both AC and DC circuits with them. Hence the relay. They power the relay with DC to control the AC going to the headlight.

I agree with you on their reasoning. IMO they should use a better handle bar sw with a seperate input for the lights. It's rediculous to have extra components on the bike. Relays and crap are looking for trouble and chew juice.

I think they use a relay so that they can use an all-in-one handlebar switch (I.E. - headlights, taillight, turn signals, horn, kill switch). Most of those switches share a common ground and 12 volt supply so it is difficult to run both AC and DC circuits with them. Hence the relay. They power the relay with DC to control the AC going to the headlight.

Ok, that's makes sense. But, if you're using the existing

AC wire through the switch to light the headlamp, you'll

not be using the common of the headlamp switch.

Therefore, all of your DC equipment like horn and t/signals

could use that common/ground wire and you can still

by-pass the need for a relay.

I think what he ment was that there is a common DC positive on the sw to run all the lights and therefore the dc hi/lo outputs control the relay, which controls the ac to the headlight. Correct me if I'm wrong PBD.

Exactly. The internal wiring of these switches combines a single source of DC , positive and ground, to the various switch functions. You've got to remember that what we're trying to do here with AC and DC combined is not the normal MC setup. The switches are made for the typical setup where the entire bike is run off of DC. In reality adding 1 relay really isn't that big of a deal to get the convenience of an all-in-one switch and is really a pretty simple solution.

Yes, a common positive lead would definitely require a relay...

Here's the Dual-Star switch color code:

Orange - Common for turn signal switch

Black/White - LH turn signal switch

White/Blue - RH turn signal switch

Yellow/Green - Common for Horn and Kill buttons (ground)

Green/Blue - Kill button

Gray - Horn button

Violet & Brown (tied together at switch) - Common for headlight switch

White - Low beam switch

Blue - High beam switch

Yellow - Running light switch to turn lights on when headlamp is on

Pink - Running light switch to turn lights on when headlight is off (note: Yellow and Pink wires are tied together.

The only off position for the running lights is the yellow dot position on the slide switch)

Looking at the above diagram, you could run positive DC on

the Orange wire and the headlamp AC on the Voilet/Brown

wires.

Power for the t/signals and horn would be seperate from the

headlamp.

I agree. My point is that there are sw's out there that have different inputs for the diff. controls, like the one I have on my bike. Why don't they just use one like that? It makes wiring alot easier as well. It simplifies the whole circuit as you can use the switches harness to make all your connections and keeps it neat and simple.

I'm going back to one of my origional statements that I believe they didn't design the kit for the WR. I believe it's their standard kit that they sell to the WR guys without changing it to suit the WR.

I think you're right. As far as I know they use the same switch in all their kits.

Yep,

I think you guys may be right.

It appears that it's the Baja switch which causes the difficulty.

It does use a shared common meaning AC can't be used with DC.

5spoke I will use the handlebar switch that you have (and your advice). It keeps everything separate. N7SLC your latest posts suddenly made everything become clear.

I am sending back the Baja Kit and ordering separte parts.

I will still need your help though if you guys are not sick of this yet. When I am finished I will provide a wiring diagram with directions for anyone interested.

Thanks for all the help guys. I am no expert when it comes to electrical so this was quite educational.

Once again, I am amazed at the commradery that I find when I log on to this site. :)

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