KAWASKAI KLR250 Light Bar Installation Guide

Tools Needed

-Philips Screw Driver

-10mm socket/wrench

-12mm socket/wrench

-13mm socket/wrench

-Electrical crimpers (can be substituted with pliers)

1. Remove the 3 Philips screws from the headlight cowl. Rotate the cowl to the side and out of the way.

2. Remove the 2, 12mm headlight bolts and the lower 10mm bolt. Remove the headlight and get access to the 3-wire plug which is plugged into the back of the headlight. See image below (Image is of a 2005 KLR250, be aware that earlier years may have different wire coloring.)

3. If you want to have an independent auxiliary switch for controlling the light bar, then run a wire from the battery (or running light positive wire) to a the new switch, then from the switch to the positive light bar wire, then wire the negative light bar wire to the frame or to the negative battery terminal. 

If you want to use the existing high-beam switch to turn on your light bar at the same time as your brights (easiest method), proceed below.

4. Use the provided T-taps (dark blue plastic crimp) to crimp onto the negative and high-beam positive wire. Using a pair of pliers works best for closing the crimpers. Be sure the crimps are fully latched around the wires. (see photo below)

5. Route the light bar wire on the right side (left if facing front of bike). It is recommended to have the light bar wires follow the same routing as the speedometer cable. Crimp the two provided spade connectors to both the black (-), and red (+) wires on the LED light bar. Slide the spade connectors into the T-taps. NOTE: LED’s are uni-polar so if you mix up the positive and negative wires the light will not work. Sometimes the spade terminals want to slide to the side of the T-tap instead of into the terminal slot which may appear to be plugged in, but will not power the light.

6. Plug the headlight back in and reinstall all bolts and cowl. Turn on the key and check the light bar for proper function.

7. Remove the LOWER 12mm fork bolt on each side. (see photo below)

8. Install the light bar assembly with the “3Dub200” logo facing upwards. The new bolts will be 13mm. Snug bolts down tightly. NOTE: New bolts may bind up on the light bar bracket, if this happens slightly loosen the spacer nut to allow the bolt to spin freely. Be sure to fully tighten both the spacer nut and the new fork bolt. 

9. Manually turn the lightbar to choose the desired height adjustment. High adjustment settings decrease the effectiveness of the lightbar. It is best to adjust the light bar at night away from other light sources. The light bar Allen bolts should be tight, but loose enough that you can manually adjust the angle with your hand. 

Thank you for your purchase! If you are satisfied with your new light I would greatly appreciate a positive review on eBay/Etsy/3Dub200.com. It would also be greatly appreciated if you post about it on any forum/Facebook group you may be a part of. If you have any issues with the product, please send me a message and I will do my best to resolve the issue.