KTM 450 EXC, 450 MXC, 525 EXC user manual

’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.

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.

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

Photo 2

Photo 1

brakeswitch

MXC
route this
wiring to
the front
of the
bike

Retain
copper
washers

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.
Bleeding the Brake: (do not
begin this process unless
you have a fresh can of brake
fluid.) Remove the lid from the

rear brake reservoir (left side
under carburetor.) Put the box
end of a 11mm wrench over the
caliper bleed nipple and install
the supplied bleed hose tightly
over the nipple. Position the
loop on the hose above the
nipple as shown in Photo 3 with
the other end of the hose in a
container to catch the fluid. Crack the bleed nipple open about 1/8 to a
quarter turn keeping the loop in the hose vertical. Slowly depress the
brake pedal to fill the hose with fluid. Pump slowly until you have brake
fluid extending up into the loop, then you can pump the pedal fairly
aggressively to drive air out of the system. The fluid above the bleed
nipple will prevent air from re-entering the system. Do not let the
reservoir go dry – add fluid as needed. Pump the pedal until there is no
more bubbles then close the nipple with the wrench. Double check the
pedal is firm and the brake works properly.

7. Taillight Prep (EXC & MXC):
Remove the taillight lens to
expose the bulb socket. Pull the
socket out of the way and drill a
13/32” hole in the taillight plastic
as shown in Photo 4. This hole is
to allow the rear turn signal and
license plate illuminator light
wires to pass through the taillight
plastic.

8. License Plate Illuminator Light
Installation: Locate the license
plate illuminator light in the kit
parts bag. It’s a small silver bolt
with two white wires coming out.
Drill a 5/16” hole in the taillight
plastic and mount it in the
location shown in Photo 4. It
should sit directly on top of the
molded ridge in the plastic.

License plate
illuminator light

Photo 4

Photo 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 these locations.

10. Rear Turn Signal and

License Plate Illuminator
Wire Routing: Route the rear

turn signal and license plate
illuminator light wires through
the hole in the taillight you
drilled in step 7. (See Photo 6)
Use a zip-tie to secure the
license plate illuminator wires
in place.

11. Rear Wiring Harness
Installation: Locate the
longer of the two gray cables
that came in the dual-sport
kit. It will have a plastic plug
on one end and several
female terminals on the
other. Position the harness
so the female terminals can
connect with the males from
the turn signals and
illuminator light. Once it is
positioned make the
following connections:

Attach one of the two

•

white wires from the
license plate
illuminator (doesn’t matter which) to the black female terminal from
the gray cable.

• • Attach the remaining white wire from the license plate illuminator to

the red wire from the gray cable.
Attach one of the two wires (doesn’t matter which) from the right
turn signal to the green wire from the gray cable.

Photo 5

Photo 6

Drill 13/32” hole here
(rear turn signal
mounting location)

Route wires through hole

Zip-tie
here

Male/female
connections

Rear wiring
harness

Photo 7