Trail Tech S-8360A User Manual

4-STK KTM ELECTRICAL SYSTEMS

STEP 1: INSTALL STATOR AND/OR FLYWHEEL:

INSTALL STATOR (AND/OR FLYWHEEL)

010-ELV-46
8300 | 8360

Tech Support: 360-687-4530

[e-mail]

MODEL-SPECIFIC NOTES

STATOR INSIDE SIDE CASE

FOR MOST KTM, SIMPLY REPLACE THE STOCK STATOR AND/OR FLYWHEEL.

1. Turn off gas, remove seat and fuel tank.

3. Disconnect fuse (e-start models only.) (Check fuse if bike won’t start at the end.)

4. Drain oil from engine case; then lay bike on its side.

5. Remove shifter to allow for easy removal of side case.

6. Remove side case, exposing the stator and flywheel.

7. Uninstall stock stator. (

8. Clean side case and bolts thoroughly, remove any dirt or pieces of gasket.

9. Install Trail Tech stator, opposite of the removal process.
specifications and bolts.
removal difficult or impossible.)

10. If installing a flywheel, a model-specific flywheel puller is required. An air-ratchet
is recommended for flywheel removal (1/2” impact wrench.) Tigh
specification
or crankshaft. Trail Tech is not liable for damage due to incorrect installation.)

11. Reinstall side case and tighten bolts to factory torque specification. Use a new
gasket if the original one has torn or become damaged.

12. Reinstall shifter and stand the bike up.

13. If you have drained the oil make sure to refill the bike to manufacturer specified
level before operation.

(do not use an impact wrench to tighten, damage may occur to flywheel

4-stk 2000-09 stators are mounted to the side case.)

(Use Loctite at your own risk, it may make future stator

FLYWHEEL INSIDE ENGINE CASE

Use factory torque

ten to manufacturer

PIP

SENSOR

4-STROKE SXF / SMR

These KTM’s come stock with a small
sized stator and flywheel. For these
models, the PIP sensor must be moved
to the rear mounting holes to allow space
for the Trail Tech flywheel. Also, the Trail
Tech provided KTM side case must be
used, instead of the stock side case.

4-STK 450/505 SX-F 2007-2009
4-STK 450/505 XC-F 2008-2009

These KTM’s use a S-8360A kit which
will replace the stock stator and flywheel
combination. A Regulator/Rectifier is not
needed for this installation as it uses the
stock unit. Install opposite the suggested
removal process provided with this kit.

TIP: ADD OIL TO ‘DRY SYSTEM’

4-STK 250 SX-F 2005-2009

For models that have a “dry system”
that do not use oil, oil can be added to
prevent excessive heat damage and rust.

1. With the bike on it’s side, add 1
of low-viscosity 5W30 motorcycle motor
oil to the engine case.

2. Using a liquid silicone gasket product,
seal the weep hole located at the bottom
of the engine case so that no oil can
escape. Make sure everything is clean
before application. Use a thin bead of
silicone on both sides of the gasket for
the best seal.

00ML

4-STK KTM ELECTRICAL SYSTEMS

AC INSTRUCTIONS:

AFTER INSTALLING A TRAIL TECH STATOR AND REGULATOR, ADD LIGHTS TO AC CIRCUIT.

010-ELV-46
8300 | 8360

Tech Support: 360-687-4530

[e-mail]

AC

- SEE NEXT PAGE FOR DC INSTALLS -

AC SYSTEMS

STEP AC1 - REGULATOR:

AC circuits can use a regulator (regulator/rectifier not required.)

AC Regulator

Yellow Regulator Wire:

Black Regulator Wire:

Regulator Ground:

Power lead. Should intersect circuit

between the stator and lights.

Ground lead. Intersects circuit between

switch and stator.

The regulator creates a frame-ground when

bolted to the motorcycle frame.

AC SYSTEMS

STEP AC2 - WIRING:

If installing an AC system, the circuit should be set up as below.

The model-specific

stator wires plug into

AC lights

wired in

parallel.

On/Off switch wired

in parallel. Two

switches may be

used to control the

lights separately.

the stock wire harness.

12 Volt AC Regulator

wired in parallel.

AC CIRCUIT CONCEPT
DIAGRAM (GENERIC):