KTM On Road Gauge USB Relocator Installation Instructions

Required Tools: Side cutters, flush cutters (or fingernail cutters), 8mm & 17mm socket, T-20 Torx and ratchet, Snap ring pliers, Pliers

Warning! Sharp tools are used in this installation. Electrical wiring is disconnected in this installation. Take proper precautions to prevent injury!

  1. Remove the plastic number plate by pulling the rubber straps from around the forks. Remove the brake and clutch cables from the slot in the number plate. Lay the number plate on the front fender.
  2. Locate the gauge, blinker, and key switch wiring and mark both sides of each plug with masking tape so each plug can be put back to its mate. It is normal to see un-used connectors behind the number plate, so labeling your wires is important. Unplug the gauge cluster, blinker indicator, and the key switch. (Fig. 1)
KTM On Road Gage Relocator
  1. Remove the plastic number plate by pulling the rubber straps from around the forks. Remove the brake and clutch cables from the slot in the number plate. Lay the number plate on the front fender.
  2. Locate the gauge, blinker, and key switch wiring and mark both sides of each plug with masking tape so each plug can be put back to its mate. It is normal to see un-used connectors behind the number plate, so labeling your wires is important. Unplug the gauge cluster, blinker indicator, and the key switch. (Fig. 1)
  3. Unsnap the cable/wiring retainers from both sides of the stock gauge mount and move wire/cables out of the way. (Fig. 2)
  4. Remove the factory gauge mount by removing the two bolts with an 8mm socket. Retain the hardware (bolts & bushings) for installation! (Fig. 3)
  5. Remove the gauge with T-20 torx bit. Retain the hardware (bolts) for installation! (Fig. 3)
  6. Remove the turn signal light using the snap ring pliers. Retain the snap ring for installation! (Fig. 4)
  7. Install the key switch, gauge, and the turn signal light in the new 3D Concepts mount with the factory hardware. Pay attention as the turn signal light has an index tab and must be oriented correctly to fit. You may find it easier to insert the bushings into the rubber grommet using silicone or o-ring lube. (Fig. 4 & 5)
  8. Install the 3D Concepts mount on the motorcycle with the factory hardware. (Fig. 6)
  9. Re-install the gauge and light switch wiring referencing your marked tape.
  10. Apply power using the key switch to test your gauge and lights/blinkers.
  11. Install the provided zip ties in the slots on the 3D Concepts mount and secure the wires and cables that were removed from the factory mount clips. Tighten the zip ties and trim with nail clippers or flush cuts. (Fig. 7)
  12. Using a pair of pliers to squeeze, install the T-Tap splices onto the negative and positive of the headlight. (Fig. 8)
  13. Install the provided harness onto the back of the USB assembly. Be sure to install the harness from the positive headlight wire to the positive on the USB and the negative headlight wire to the negative on the USB! Tying into the headlight, allows the USB to be powered with the key. If you prefer the USB to be on its own hot buss, you will need longer wire to run to the battery.
  14. Apply power with the key switch to test the USB installation.
  15. Secure the wiring with the factory straps or zip ties.
  16. Install number plate extensions by removing the blinkers from the number plate.
  17. Place the extensions as shown (Fig. 9) and reinstall the blinkers.
  18. Install the rubber straps on the number plate extensions.
  19. Install the number plate by inserting the lower studs into holes in the front fender and fasten the rubber straps around the forks.
  20. Go get dirty!

FIG. 1

FIG. 2

FIG. 3

FIG. 4

FIG. 5

FIG. 6

FIG. 7

FIG. 8

FIG. 5

FIG. 6

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