KTM DUAL SPORT KIT INSTALLATION MANUAL - Manuals

Page 2 - Photo 3; Remove the lid from the; Do not let the; Pump the pedal until there is no; Photo 4; Locate the license

failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install the copper crush washer from the stock bolt under the switch (Photo 2). Torque to 25 lbs. Photo 3 Bleeding the Brake: (do not begin this process...

Page 3 - Looking at the; Photo 5; Route the rear; Photo 6; Route wires through hole; Photo 7

9. Rear Turn Signal Installation: Looking at the inside edge of the taillight, locate the slightly raised “guides” on each side (see Photo 5). These are where the rear turn signals will mount on the taillight. Mark the center of these guides with an awl and drill a 13/32” hole through the center of ...

Page 4 - Photo 8; EXC; - You may now reinstall; MXC; – Since the MXC fender does; Photo 9; Mid Harness Installation:; Locate the

Attach one of the two wires (doesn’t matter which) from the left turn signal to the white wire from the gray cable. • • Photo 8 MXC Taillight Mounting Hardware Locations Attach the two remaining wires from the turn signals to the black double-female connector from the gray cable. Once the connection...

Page 5 - Mount the; EXC’s; use the existing; MXC’s; use the two

Photo 14 Photo 12 13. Front Turn - Signal Installation: Mount the front turn-signal mounting bracket to the upper triple-clamp as shown in Photo 12. Mount the front turn-signals to this bracket. EXC’s use the existing bolts to mount this bracket. MXC’s use the two 6x12mm bolts found in the parts bag...

Page 6 - You will now make all the necessary wiring; EXC Only; - Unplug the plastic terminal with the two white wires from; MXC Only; – Plug the blue wire from the relay into the stock yellow

17. Kill Wire Extension Installation: Locate the black/white and green two- wire extension in the dual-sport kit parts bag. It has a ring terminal and female connector on one end and two females on the other. Secure the ring-terminal to the ground bolt under the fuel tank (same bolt the stock kill b...

Page 8 - It is important that all the wires be properly routed and secured.

The switch panel in this kit controls all the lighting functions in one compact package. Using the lighting selector, push the switch to the second position. The rear taillight should come on. Test the brake-light. Test the turn signals. Honk the horn (unless its after 11 PM!). Because the headlight...

Page 9 - TROUBLESHOOTING; The stock headlight switch must be in the “on” position

off the road. Make sure all the silicone rubber connector boots and the connectors are pushed firmly together and no bare metal is exposed. TROUBLESHOOTING Nothing happens when you turn the power switch on: • • • • • • • • • • Fuse is blown. Check for bare wire or terminal shorting against the frame...

Page 10 - Baja Designs

Baja Designs 185 Bosstick Blvd. San Marcos, California 92069 760.560.2252 www.bajadesigns.com