KTM Radiator Guard Installation Instructions for
1998-2003
2-Strokes 200/250/300/380 EXC, MXC,
& 2000 400/520 EXC, MXC Part
#12-02
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. Threaded Hex, side panel mt.(eccentric)
2 ea. 6mm x 20mm hex/washer bolts
1.
Remove seat, side shrouds, & tank.
2.
Remove plastic brackets from radiator sides and set aside.
3.
Remove stock louvers and set aside. Remove stock bolts from radiators
and set aside.
4.
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.
5.
Clamp small “L” bracket to the top of the lower frame tube using the
#20 hose clamp provided. (as shown in
Picture #1)
6.
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!
7.
Bolt
threaded hex side panel mounts provided. (as shown in picture #3) Stock part can
be used but shrouds will stick out 3/8” farther.
8.
Reinstall tank, side shrouds (using 6mm x 20mm hex/washer bolt provided)
and seat.
9.
Roost!
Picture #1 Picture #2
Picture #3
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