KTM Radiator Guard Installation Instructions for

2001-2003 4-Strokes 400/450/520/525 EXC, MXC, SX, Part #12-01

Parts included:    1 set rad. guards                                 1 cross bar assy.

                          4 ea. 6mm x 14mm shcs                      2 ea. 6mm x 8mm fhcs

                          1 #20 hose clamp                                2 ea. 6mm x 20mm                                                                                             washer/hex bolt

1.      Remove seat, side shrouds, & tank.

2.      Remove stock louvers and set aside. Remove stock bolts from radiators and set aside..

3.      Install long bracket & “L” bracket assembly above the frame tubes. (as shown in picture #1) Note: pull radiators off of frame mount pins to allow additional room to get brackets snaked through and remount once you have bracket in position.

Picture #1

4.      Clamp small “L” bracket to the top of the lower frame tube using the #20 hose clamp provided.             (as shown in Picture #1)

5.      Bolt radiator guards in place using 6mm x 14mm bolts provided. Tip: A ball-end hex allen wrench is the easiest way to install using access holes provided!  Tip: Be sure to start bolt straight! Install 6mm. x 8mm flat head cap screws through radiator guards into long bracket ends. (as shown in picture #2) Use Loctite and do not over tighten!

Picture #2

6.      Reinstall tank, side shrouds (using 6mm x 20mm washer/hex bolts – provided) and seat.

7.      Roost!

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