Trail Tech 90 WATT HIGH OUTPUT DC ELECTRICAL SYSTEM KIT FOR FOUR STROKE KTM 450/505 SX-F/XC-F 2007/2012 AND 2008 450 SMR S-8360A - Manual

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4-STK KTM ELECTRICAL SYSTEMS
STEP 1: INSTALL STATOR AND/OR FLYWHEEL:
INSTALL STATOR (AND/OR FLYWHEEL)
STATOR INSIDE SIDE CASE
FOR MOST KTM, SIMPLY REPLACE THE STOCK STATOR AND/OR FLYWHEEL.
1. Turn off gas, remove seat and fuel tank.
3. Disconnect fuse (e-start models only.) (Check fuse if bike won’t start at the end.)
4. Drain oil from engine case; then lay bike on its side.
5. Remove shifter to allow for easy removal of side case.
6. Remove side case, exposing the stator and flywheel.
7. Uninstall stock stator. (4-stk 2000-09 stators are mounted to the side case.)
8. Clean side case and bolts thoroughly, remove any dirt or pieces of gasket.
9. Install Trail Tech stator, opposite of the removal process. Use factory torque
specifications and bolts. (Use Loctite at your own risk, it may make future stator
removal difficult or impossible.)
10. If installing a flywheel, a model-specific flywheel puller is required. An air-ratchet
is recommended for flywheel removal (1/2” impact wrench.) Tighten to manufacturer
specification (do not use an impact wrench to tighten, damage may occur to flywheel
or crankshaft. Trail Tech is not liable for damage due to incorrect installation.)
11. Reinstall side case and tighten bolts to factory torque specification. Use a new
gasket if the original one has torn or become damaged.
12. Reinstall shifter and stand the bike up.
13. If you have drained the oil make sure to refill the bike to manufacturer specified
level before operation.
FLYWHEEL INSIDE ENGINE CASE
MODEL-SPECIFIC NOTES
4-STROKE SXF / SMR
These KTM’s come stock with a small
sized stator and flywheel. For these
models, the PIP sensor must be moved
to the rear mounting holes to allow space
for the Trail Tech flywheel. Also, the Trail
Tech provided KTM side case must be
used, instead of the stock side case.
4-STK 450/505 SX-F 2007-2009
4-STK 450/505 XC-F 2008-2009
PIP
SENSOR
These KTM’s use a S-8360A kit which
will replace the stock stator and flywheel
combination. A Regulator/Rectifier is not
needed for this installation as it uses the
stock unit. Install opposite the suggested
removal process provided with this kit.
TIP:
ADD OIL TO ‘DRY SYSTEM’
4-STK 250 SX-F 2005-2009
For models that have a “dry system”
that do not use oil, oil can be added to
prevent excessive heat damage and rust.
1. With the bike on it’s side, add 100ML
of low-viscosity 5W30 motorcycle motor
oil to the engine case.
2. Using a liquid silicone gasket product,
seal the weep hole located at the bottom
of the engine case so that no oil can
escape. Make sure everything is clean
before application. Use a thin bead of
silicone on both sides of the gasket for
the best seal.