KTM EXC 2004-2007 rear fender REMOVAL

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Filed Under (KTM) by admin on 29-01-2012

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Remove lower section of rear fender • Using care not to damage the threads, drill 1/8″ pilot hole up through subframe and rear fender (fig1) • Remove fender, enlarge pilot hole in upper subframe with 1/4″ drill, do not drill out threads- take care not to damage threads in subframe. • Enlarge holes in fender to 5/8″ • Install upper section of rear fender, insert enclosed 5/8″ spacers in fender holes (fig.2) • Install cross brace (bolt holes closer to front of bike) using enclosed M6 X 50mm button head bolt (fig 3) • Re-install lower fender section using original stepped washer with enclosed 6mm nuts (fig 4) • Install side brackets as shown in fig 5 – replace subframe bolts with enclosed flat head bolts at forward mounting points if necessary.

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