Trail Tech 70 WATT HIGH OUTPUT DC ELECTRICAL SYSTEM FOR HONDA CRF450R 2005-2008 AND CRF250R 2004-2009 SR-8201A - Manual

010-ELV-59
S-8200
Tech Support: 360-687-4530
[email protected]
DC CONVERSION
CRF 250/450R DC CONVERSION
INSTALL ELECTRICAL SYSTEM:
All wires are connector and color matched. An experienced technician can complete this installation
without instructions by matching connectors and wire colors.
Remove seat to expose the air box.
Remove gas tank.
Using a 13/64” (5.15mm) drill bit, mark and drill two holes lining up the Trail Tech battery mounting plate to the bike frame. After
the holes are drilled, use the two included M6 self-tapping screws to mount the mounting plate to the bike frame (Fig.1.)
Install the battery bag to the mounting plate, as shown below. Pull the strap tightly to securely hold the battery (Fig.2.)
1:
2:
3:
4:
Use a 13/64” (5.15mm) drill bit to drill a hole * in the bike
frame (Fig.3.) Use the included M6 self-tapping screw to
mount the regulator/rectifier (Fig.4.) *MAKE SURE THE
HOLE FOR THE REGULATOR/RECTIFIER IS LOW ENOUGH
TO ALLOW THE GAS TANK TO BE RE-INSTALLED.
5:
Fig.3
Fig.2
Fig.4
Fig.5
Fig.1
Install Trail Tech stator (See reverse side of instructions.)
Install the wiring harness:
6:
7:
A:
B:
C:
D:
Plug the wire harness white 4-pin connector into the
mating connector on the regulator/rectifier. (Fig.4.)
Connect the yellow wires from the wire harness to the
yellow wires from the stator.
Connect the red and black wires from the wire harness to
the red and black wires from battery. (Fig.1 and Fig.2.)
Connect the remaining stator wires to the stock wires
that the stock stator was disconnected from.
To wire in a headlight or other electrical accessory, connect
the light’s red and black wires to the battery. Add a switch
between the light and battery. The light will never shut off if
it is wired directly to the battery with no switch (drains the
battery.)
8:
MOUNT REGULATOR/RECTIFIER AS LOW AS POSSIBLE.