Instructions for installing BDSB performance fuel rail for KTM & Husqvarna bikes. For 2017- 2020 SXF / XCF / FC / FX & 2017-2020 KTM & Husky 4 Strokes 250 / 350 / 450 / 500 / 501
This pic shows you the fuel rail you are removing from the bottom of the throttle body. It is the black plastice piece my finger is on. The two 8mm bolts that my other finger is on are the ones you will remove to take it off of the throttle body. The throttle body is offf the bike here so it’s easier to see. You do not have to remove the throttle body from the bike to easily get the fuel rail off. It’s easily accessible.
The first thing you’ll do is un-clip your quick disconnect on the fuel line by squeezing the metal clip in and pulling the 2 halves apart. Watch your eyes as some fuel may quirt out.
You can easily get to the two 8mm bolts that hold the fuel rail on with a wrench or small socket. Remove these two and pull the fuel rail and injector out of the body. Un-clip the wires from the injector by squeezing the tabard while pulling down.
Pull the fuel rail and injector apart. I’d highly suggest putting some grease or lubricant on the O ring that’s on the injector before sliding the injector into the new fuel rail. You may beed to poke the O ring into the new injector with a small screwdriver to get it to go on easier.
This is what the unit looks like assembled now. Use the allen screw provided in the kit instead of the bolts you took out. If the injector seal stayed in the throttle body, it’s easier to pick it out and install on the injector first. Then assemble all together.
You will now need to remove the fuel line from the original fuel rail and install the new one we included. It’s easier to just pinch the stock clamps on the sides with side snip pliers until the ends come up. Then just grab with the snips and twist and pull apart.
Make sure you re-install the injector clip. The line that you removed from the stock fuel rail will work better on all the off road models if you turn it around to re-install on the new fuel rail. It will make the bend towards the tank fuel fitting better. You will find that loosening the nut on the bottom of the tank fuel fitting, so that you can rotate it rearward, will let you re-use both of the stock lines and let them easily reach each other.
Be sure to tighten the tanks fitting back down. Re-clip lines and make sure all hose clamps are tight. Yes, I know the one on the tanks line is missing here. Use the extra fuel line provided if needed.