KTM DUAL SPORT KIT INSTALLATION MANUAL - Manual
KTM DUAL SPORT KIT INSTALLATION MANUAL – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.
Table of Contents:
- 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
- Page 3 – Looking at the; Photo 5; Route the rear; Photo 6; Route wires through hole; Photo 7
- Page 4 – Photo 8; EXC; - You may now reinstall; MXC; – Since the MXC fender does; Photo 9; Mid Harness Installation:; Locate the
- Page 5 – Mount the; EXC’s; use the existing; MXC’s; use the two
- 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
- Page 8 – It is important that all the wires be properly routed and secured.
- Page 9 – TROUBLESHOOTING; The stock headlight switch must be in the “on” position
- Page 10 – Baja Designs
’04-‘05 KTM 450/525 EXC & MXC
DUAL SPORT KIT INSTALLATION MANUAL
1. Get a degree in Mechanical and Electrical Engineering. (kidding)
2. Remove the seat and fuel tank. Unplug and remove the kill button and its
wiring.
3.
EXC
– Unplug and remove the headlight.
MXC
– Remove the front
number plate.
4.
EXC
- Unplug the stock taillight from the bike’s wiring harness (plastic
connector at the front of the airbox) and remove the rear fender/side panel
plastic from the bike. Unbolt and
remove the stock taillight from the rear
fender.
MXC
– Remove the rear
fender/side panel plastic from the bike.
Photo 1
MXC –
route this
wiring to
the front
of the
bike
5.
MXC Only
– Locate the stock lighting
wiring harness zip-tied under the
frame back bone (see Photo 1.)
Remove the securing zip-ties and
route this wiring forward to the area
behind the headlight. Route along the
right side of the frame using the
factory wire guide clamp.
Photo 2
Retain
copper
washers
brakeswitch
6.
Brakelight Switch Installation:
The
KTM kit uses a hydraulic brakelight
switch. This requires replacing the
rear master cylinder banjo bolt with a
specially made switch. Installing the
switch requires bleeding the brake.
If
you do not feel competent bleeding
your rear brake, please refer this
job to a qualified mechanic, as
"Loading the manual" means you need to wait until the file loads and becomes available for online reading. Some manuals are very large, and the time they take to appear depends on your internet speed.
Summary
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...
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 ...
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...
