Dualsporting Roger's KLX 300R. Tusk kit.

[FastDoc]

We got it done.

Nothing too hard but it took about 4 hours start to finish. Roger did most of the grunt work, I did the wiring and delicate stuff. Praise God it worked perfectly the first try.

It's a great kit, I would recommend it.





Roger fitting the inner rear fender. This was the most time consuming part of the job.



The kit layed out.



Before.



After .



The plate is not 'real'. It's just for show, an old one I had laying around.





The battery and rear portion of the wiring harness.



The blinkers and horn. The headlight is the original KLX's, running off the alternator, no battery. Somehow we screwed up the headlight, must have unplugged something. Will fix that later. It was too long a day to do it tonight.



Small rechargeable battery pack.









Fiddley work.

Roger and I had a great time. He owes me pizza and beer. BIG TIME. 8)

[Weldangrind]

Thanks for the pics and report. The switches look good.

So, the KLX didn't already have a battery? If it did, would you be able to tap into it, rather than adding the NiCd pack?

Is the stock headlight DOT, or will Roger require a different unit for the street?

[FastDoc]

The headlight is not DOT and lacks a high beam although that is not required per se. We're hoping the inspector won't notice, and if he does Roger will have to spring for a DOT approved Polysport, but those are not expensive.

The KLX300R lacks a battery.

It may turn out that a licensed motorcycle shop, ie ANDY, can do the inspection. If that's the case we're in. 8)

[MICRider]

Clean looking install! The blinkers are nice and compact as well, should be pretty durable when off roading. Thank you for showing us the install, Roger is a lucky man to have you for a friend and riding companion

[FastDoc]

I'm lucky to have Roger as a friend and riding companion :wink: .

Thanks for the kind words.

[fishman10]

that kit looks exactly like the kit i got from drc,,,but i had to add a acerbis d.o.t. headlight here in PA,,,,,,,my first attempt did not go so well as i tried to cheap out an not purchase the small battery pack, an for some reason it ruined my regulator,,,incendently I also installed it on a klx300.Once i ordered a new reg. and battery pack from baja designs all was well.

[FastDoc]

This system is compleatly seperate from the bikes OEM electrical system. It does not self charge, you have to plug it in between rides! Considering how it is to be used though that's fine.

The bikes stock headlight and alternator remain.

[fishman10]

Hmmm,, i had a friend who is an electrician help wire mine and he indeed did wire it to charge, i think the baha designs battery pack included directions to do so. Incendently the drc kit came with a holder for double a batteries to get you thru inspection,,cause in some states the lights must light without the engine running,,,BTW hope your conectors in that kit where of better quality,, mine in the drc kit where of very poor chinese quality and we replaced alot of them.

[FastDoc]

The connectors were OK, anf the harness appeared well made.

I read the law and requirements for Washington and there is no mention of the lights having to be on with the motor off.

[Weldangrind]

I think that our inspection rules dictate that the tail light must come on with the key switch, and it must stay on for X number of minutes without the engine running. Not sure how many minutes, but 15 comes to mind. It just confirms that you have enough battery reserve to be seen from behind at night in the event of a charging failure. AA batteries (or the NiCd batteries in the Tusk kit) should be more than capable.

[FastDoc]

It will be interesting to see if it passes inspection. If Andy can do it I'm sure we're good :wink: .

If Roger passes easily, I'll likely do The Dirt Rat.

[SpudRider]

Thanks for posting the nice thread, and photographs, Doc! I love Tusk products, and Rocky Mountain ATV/MC!

Spud