2004-2005 KTM 250/ 400/ 450/ 525 Side Panel Fuel Tank removal and Installation Instructions

0

Filed Under (KTM) by admin on 22-01-2012

download
1. Remove airbox cover. Drill stock rivet nut in frame tube through with a ΒΌ” drill as shown in Photo 1. Drill completely through frame tube. We suggest you make a small guide hole in the top of the frame tube first so that you drill straight through the frame member and not come out the side of the frame tube. Photo 1 .Install Lower mounting bracket as shown in Photo 3 noting its orientation. Install the aluminum cone into the recess at the bottom of the stock airbox , then bolt the bracket on with the 6 x 70 mm bolt. Nylock nut threads to top of bolt on top of frame tube as shown in photo 2. Photo 3 2 3. Install the upper mounting bracket shown in Photo 4. Note that in either the MXC or the EXC installation four to six of the 6 x 18 mm fender washers should be installed between the bracket and the subframe. The counter-sunk hole should be positioned toward the rear wheel. Leave the bracket slightly loose until step 6. Photo 4 The best routing for the fuel line (Photo 5 & 6 ) requires drilling holes in the airbox. See Step 4 for hole locations. 4. Drill a 3/8″ hole at the front left corner of the airbox as shown in Photo 6. Make sure the location you choose will not result in the hole coming out behind the frame tube or into the rubber airbox boot. Be very careful drilling this hole.

Ridley Auto-Glide Installation Manual

0

Filed Under (Ridley) by admin on 01-11-2010

download
Place motorcycle in a secure upright position 2) Remove saddle bags (if applicable) 3) Remove rear fender mounting bolts (3 each side) 4) Tap indicated rear fender mounting holes with a 3/8″ – 16 tap. (2 holes each side) It is highly recommended that cutting/tap oil is used. Use care when tapping holes. Be certain to tap holes completely through. 5) Ensure 2 large attachment bolts are tight. 6) Attach Bracket C (left) and Bracket D (right) to rear fender rail. Use new bolts provided on outer tapped holes (2) and one of the longer original bolts for center hole. Place one washer between brackets C & D and rear fender rail on each bolt. (3 each side) Place washer and thin nut on inside of rear fender on new bolts (2 each side) These replace original fender washers. It may be necessary to reattach saddle bag attachment hardware when attaching brackets C and D. All saddle bag hardware should be attached to the OUTSIDE of brackets C and D. 7) Attach front of Bracket A (left) and B (right) to existing hole in motorcycle frame just above swing arm pivot. 8) Attach rear of bracket A (left) B (right) to TOP of forward hitch arms. Snug bracket A and B attachment bolts at this time. 10) Attach top of Bracket E (left) and F (right) to outside of lower tabs on bracket C & D. 11) Attach bottom of brackets E and F to top of rear hitch plate. 12) Tighten bolts at this time. Use caution not to over tighten and strip tapped holes in rear fender rail. Bracket Identification