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KTM 04-`05 KTM 450/525 EXC & MXC manual

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Table of contents for the manual

  • Page 1

    ’04-‘05 KTM 450/525 EXC & MXC DUAL SPORT KIT INSTALLATION MANUAL 1. Get a degree in Mechanical and Elec trical 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 [...]

  • Page 2

    failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replac e 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 unless you have a fresh can of brake fluid.) Rem[...]

  • Page 3

    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 each one. Mount two of the turn signals to t[...]

  • Page 4

    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 Hardw are Locations Attach the two remaining wires from the turn signals to the black double-female connector from the gray cable. Once the connections are made, drill several small holes and z[...]

  • Page 5

    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 to mount this bracket. 14. Lens, Flasher, H[...]

  • Page 6

    17. Kill Wire Extension Installation: Locate the black/white and green two- wire extension in the dual-sport kit par ts 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 button was removed from in step 3.) Attach the fem[...]

  • Page 7

    19. Mid-Harness Connections: You will now make all the necessary wiring connections under the fuel tank and seat. Under the fuel tank, locate the unused white 2-wire connector from the stock wiring harness (see Photo 14.) It may be bundled up in the stock wiring. Free this connector and attach it to the corresponding 2-wire connector from the Baja [...]

  • Page 8

    The switch panel in this kit controls all the lighting functions in one compact package. Using the lighti ng selector, push the switch to the second position. The rear taillight should come on. Test t he brake-light. Test the turn signals. Honk the horn (unless its after 11 PM!). Because the headlight is powered directly off the coil, (not backed u[...]

  • Page 9

    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 wir e or terminal shorting against the frame or another wire. 6-pin conne[...]

  • Page 10

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