DENALI KTM EXC-F, XC-W and XCF-W LED Headlight Mount Instruction Manual
- June 8, 2024
- DENALI
Table of Contents
DENALI KTM EXC-F, XC-W and XCF-W LED Headlight Mount
Thank you for choosing DENALI
We know you would rather be riding your bike than wrenching on it, so we go the extra mile to make sure our instructions are clear and as easy to understand as possible. If you have any questions, comments, or suggestions don’t hesitate to give our gear experts a call at 401.360.2550 or visit WWW.DENALIELECTRONICS.COM
Please Read Before Installing
DENALI products should always be installed by a qualified motorcycle technician. If you are unsure of your ability to properly install a product, please have the product installed by your local motorcycle dealer. DENALI takes no responsibility for damages caused by improper installation. Caution: When installing electronics it is extremely important to pay close attention to how wires are routed, especially when mounting products to the front fender, front forks, or fairing of your motorcycle. Always be sureto turn the handlebars fully left, fully right, and fully compress the suspension to ensure the wires will not bind and have enough slack for your motorcycle to operate properly
Installation Tips
We strongly recommend using medium strength liquid thread locker on all screws, nuts, and bolts. It is also important to ensure that all hardware is tightened to the proper torque specifications as listed in your owner’s manual. For included accessory hardware please refer to the default torque specifications provided below. Inspect all hardware after the first 30 miles to ensure proper torque specifications are maintained.
Bolt Size
| in-lbs| ft-lbs| Nm
---|---|---|---
M3| 0.0 in-lbs| –| 1.0 Nm
M4| 23.0 in-lbs| –|
2.5 Nm
M5
| 44.5 in-lbs| 3.5 ft-lb| 5.0 Nm
M6| 78.0 in-lbs| 6.5 ft-lbs|
9.0 Nm
M8
| –| 13.5 ft-lbs| 18.0 Nm
M10| –| 30.0 ft-lbs|
41.0 Nm
M12
| –| 52.0 ft-lbs|
71.0 Nm
Hardware Sizing Guide
Not sure what size bolt you have? Use this ruler to measure screws, bolts,
spacers, etc.
Remember, the length of a screw or bolt is measured from the start of the
“mounting surface” to the end of the screw, so only include the screw head
when measuring countersunk screws.
What’s In The Box?
(a) D7 Face Plate…………………………………………………………….Qty 1
(b) D4 Face Plate…………………………………………………………….Qty 1
(c) Mounting Bracket………………………………………………………..Qty 1
(d) M5x14 ISO 7380………………………………………………………..Qty 5
(e) M5 Washer DIN 125…………………………………………………..Qty 10
(f) M5 Nut DIN 985………………………………………………………….Qty 5
(g) KTM Wiring Adapter…………………………………………………….Qty 1
(h) DataDim™ Controller……………………………………………………Qty 1
Installing The Enduro Headlight
Assembling The Mounting Bracket
This Enduro Headlight Mounting Kit is a designed to replace the OEM headlight
of KTM
EXC-F, XC-W and XCF-W models. The LED headlight will plug directly into the
OEM harness and will be controlled from the original headlight light switch.
Step One: Begin by installing the aluminum face plate to the mounting
bracket (c) using the M5 hardware (d,e,f). If installing the round D7 LED
light use face place (a), if installing the square D4 LED light use face plate
(b).
Installing The Mounting Bracket
Step Two: Remove the headlight mask from the motorcycle and uninstall the
factory sealed beam headlight. Keep the factory self tapping screw from the
lower headlight mounting tab as it will be re-used during the installation of
the LED headlight.
Step Three: Use the M5 hardware (d,e,f) to attach the mounting bracket to
the upper headlight mounting tabs.
Step Four: Re-use the factory self tapping screw to attach the mounting
bracket to the lower headlight mounting tab. The screw should be threaded into
the hole closest to the front of the headlight mask.
Installing The D4/D7 LED Light
Step Five: Remove the hinge from the D4/D7 LED light pod by removing the
M8 bolts on either side of the pod. Be sure to keep the bolts, flat washers,
lock washers and rubber grommets. They will be re-used to install the light
pod into the headlight mask.
Step Six: Insert the D4/D7 light pod into the mask from the front side,
then re-use the M8 bolts, flat washers, lock washers and rubber grommets to
attach the light pod to the mounting bracket.
Note: For maximum downwards adjustability, pull the light pod to the top
of the slotted mounting points before tightening the M8 hardware.
Wiring The Enduro Headlight
Step Seven: Plug the red 4-pin connector of the KTM wiring adapter (g)
into the factory headlight connector.
Step Eight: Plug the black 6-pin connector of the KTM wiring adapter (g)
into the Data Dim Controller (h).
Step Nine: Plug the black 3-pin connector of the KTM wiring adapter (g)
into the D4/D7 pod.
