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

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1. Remove airbox cover. Drill stock rivet nut in frame tube through with a ¼” 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.

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