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

Dc conversion, Install electrical system

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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.