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Clean the engine case where TJD Case Saver is to be installed by removing any oil, dirt, and grease. Make sure to use a slovent like cleaner that dries quickly such as brake cleaner, speedy 500, rubbing alcohol, or electrical contact cleaner, etc.


Apply a thick layer of HIGH TEMP (I prefer Black Adhesive type) RTV type of permatex silicone to the backside of the TJD Case Saver. Make sure to get complete coverage and it should be about 1/16th of an inch thick or more. A thick bead on the edge allows the excess to squeeze out making a good seal. Make sure to wipe the excess clean for a nice sealed look.


Align TJD Case Saver in the correct position on the case making sure there’s no edge hanging over or on sideways. Press and hold firmly for a few minutes. Use masking tape or painters tape to hold it in place overnight while curing.


Let it dry overnight for a full cure in 24hrs. Now go ride knowing you have some Trailjammer Designs protection keeping you safe out there.





Installation Instructions



KTM 950/990 2004-2013 ADVENTURE BIKES


Thank you for purchasing a Trailjammer Designs Adventure Exhaust Guard and Passenger Heat Shield. We hope you enjoy this amazing new product. This exhaust guard will help keep the hot exhaust off you and your passenger at all times while still letting the bike cool and hot exhaust temps exit out the back. No more melting boots!


Remove Passenger Peg mounting bolts


Remove sub-frame mounting bolt on clutch cover side of bike (if sitting on bike, right side)


Place Trailjammer Designs Adventure Exhaust Guard under the plastics and align mounting holes. The exhaust guard mounts over the passenger peg and uses OEM bolts to bolt exhaust guard and passenger peg back on. (Aftermarket bolts are included if your OEM bolts are too short). The sub-frame bolt and OEM washer mount over the Trailjammer Designs Exhaust Guard. Make sure to Loctite all 3 mounting bolts when installing.


Adjust exhaust guard (if needed). The TJD exhaust guard ‘may’ be touching some aftermarket pipes in one area. This is normal. The aluminum alloy used has some flex to it and can be flexed into the desired position if needed. It does not hurt anything if guard touches pipe. Just a slight pull out toward the plastics will help clear larger aftermarket pipes and 2-into-1 exhaust systems.


We hope you enjoy your new TJD Exhaust Guard. Have some great trips!

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Hand built in San Jose, CA right here in the U.S.A.

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