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’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