Manual for LC8 Racing System

Thank you for your purchase and support. Installation of the filter is a straightforward process. It differs slightly for 990 vs 950 and those differences are pointed out in each step respectively.

Your Muller Motorsport  filter kit contains the following components:

1. Two Pre-oiled foam filter elements
2. One base plate; either for a 950 or a 990 (990 is identifiable by the small

holes for the air temperature sensor)

1. One filter cage plate with filter posts
2. One crankcase breather hose filter with a clamp
3. Two silicone baseplate seals
4. Air temperature sensor bolts usable only for 990
5. Two filter system main bolts
6. One pair of disposable gloves for manipulation with pre-oiled filters

Removing your existing filter

Original KTM Air-box

• If you have the original air box on your bike, you will need to remove it entirely and in doing so, you will have to detach the throttle bodies or carburetors from the engine. On the 990 models, remove the air-temperature sensor from the top of your airbox and make sure not tolose its o-ring. You will need to install this sensor on the new baseplate later with the hardware provided in the kit. Your crankcase breather hose is attached to the top lid of the airbox so please remove it from the airbox and set it aside for now. Please refer to your KTM service manual for detailed instructions on the airbox removal.
• Install the throttle bodies or carburetors back onto the engine without the airbox. Make sure the rubber boots fit correctly and the clamps are in the grooves of the boots when tightening them. Route the cables to their original positions making sure that none of them interfere with the throttle assembly.
• Tip: On the Adventure models, position the clamps in such a way that you can access them without removing the tanks using a long extension. This makes future maintenance easier.

Other air filters

• If you have another brand of open air filter system in place, remove all its components. Save the air-temperature sensor and its oring if you have a 990. Our kits include everything you need to install and operate a complete system.

Installing the kit

1. Silicone Seal rings 
1. Install one silicone seal o-ring over each throttle body or carburetor. They do NOT need to be oiled.
2. Base-Plate
1. Place the filter base plate over the throttle bodies with the protruding threaded portion of the nut rivets on the underside of the plate. 990 only: Before installing the base-plate, install your air temperature sensor with the provided bolts and nuts. The plug of the sensor faces under the plate similar to the nut rivets. Re-use the o-ring that you saved earlier, between the sensor and the plate. Don’t over tighten the screws. There should be a very small gap visible between the sensor and the plate that’s filled with the o-ring. Plug the air-temperature sensor connector to the sensor and install the filter baseplate over the throttle bodies with the wiring of the sensor under the plate. The sensor should end up in the front of the throttle bodies.
3. Trumpets (Velocity stacks)
   1.  Install the trumpets over the baseplate. They should click into place (orturn and click), securing the base plate in the same way as when they were in your original airbox. Note: the 950 Super Enduro trumpets do not need to be cut as with some other filter kits.
4. Assembling the filter
   1.  Insert the filter cage and posts into your oiled filter. Pull the cage down into place so the rim rests on the rim of the filter. Press on the grommets to bottom out against the posts. The entire filter cage plate should be inside your foam filter.
5.  Installing the Filter
   1. Put the foam filter and the filter cage assembly over the baseplate; position it so you can’t see the baseplate looking at the filter from above. Feed the screws into the grommets on the filter. Try to engage both screws with the threads on the baseplate, then tighten them at the same time with both hands or gradually with a few turns at a time on each. Do not tighten one all the way down with the other one loose. The base of the foam is designed to compress. This is intentional and it will make a complete seal every time. 
6. Inspect the filter
   1. This is an important step. Look around the filter, run your fingers all around it to make sure the filter is sitting over the plate evenly all around with no part of it hanging out more than other areas. If anything is uneven, the cage plate may not have been installed into the filter correctly. Remove and correct the fitment of the filter cage into the foam filter if necessary and repeat the installation.
7. Crankshaft breather filter
   1. Your kit includes a crank-shaft breather filter. Install that at the end of the breather hose reusing your existing KTM clamp or using supplied one and secure it to the frame of the bike away from the main air filter. 
   2. Use zip-ties? to secure the hose to the frame of the bike as high up as possible without it interfering with anything. 
   3. This filter does not need to be oiled. Inspect it every time you replace the main air filter for excess dirt and dust. It is completely serviceable by cleaning it of excess engine oil vapour that emanates from the crankcase breather hose.
8. Jetting / re-mapping
   1. Every time any component of the engine related to air intake, exhaust and fuel type is changed you should update the jetting (950) or re-map the ECU (990), accordingly. This air filter system is no exception however, if you already had an open air filter on your motorcycle such as those made by ITG, you may find the settings not requiring any change. If you are switching from factory stock air box to the system, you should update the jettings/map otherwise you risk damaging the engine by running too lean. We avoid recommending a specific jetting or map because there are too many variables to result in the best set up. A good, safe place to start is using larger main jets 950 and a richer map for 990. Depending on your local conditions and other modifications to your bike, you may need to further change the jetting/map to get the best results. Ultimately, taking your bike to a shop with a dyno and professional staff will provide you with the best outcome.
9. Baseline for 950
   1. Main jets to 170 front and 175 rear.
   2. Leave all other jets stock 
   3. Floats height to 3.5mm 
   4. Needle clips on the 3rd position middle groove.
10. Baseline for 990
    1. Option one: Akrapovic map provided by KTM
    2. Option two: Map known as Zuber’s map made by Zuber on advrider.com https://www.dropbox.com/s/fq5qccj3hxuxidt/Zuber9-KM601EU1102002Map.hex?dl=0
       
11. Servicing your filter kit: 
    1. Your Muller Motorsport filter system uses a triple layer foam filter that requires regular maintenance. Your filter came pre-oiled, you may use any air filter degreaser or cleaner available on the market.
    2. Oil your cleaned filter using your favourite filter oil, it does not matter which, any named brand is fine.
    3. NEVER run your bike without a filter or with a dry filter as filtration depends on filter oil as part of the filtration process.

Important Notes:

• As with all Muller Motorsport products, these are intended for racing and do not claim to adhere to any local laws or warranties.
• This air filter system is intended for off road / racing use and therefore we make no claim to compliance with emissions or warranty. Use at your own risk.
• Please follow your choice of filter oil and filter oil cleaner’s instructions. Make sure that you use filter oil intended for foam air filters for off-road motorcycles, used in dusty and wet conditions.
• Since many motorcycles are used seasonally or occasionally, you must maintain your filter with fresh oil as required to avoid running a compromised filter. When in doubt, maintain your filter system by cleaning and using correct fresh oil. It is very important to remove all the cleaning fluids off the filter and let it dry before re-oiling the filter.
• Due to many factors including but not limited to the previous state/age of your motorcycle and your maintenance of it, Muller Motorsport can not be held liable for any damage or wear whatsoever; use at your own risk.
• Please note that oil based foam air filter systems are designed to capture a lot more dirt than the standard dry systems as such, require more maintenance than the standard. This is vital to maintaining a filtration system that performs as designed. We have designed this system to be easy to service and the cageless setup allows you to carry a spare filter with you. We highly encourage you to service the filter periodically. We can not recommend a set schedule for maintenance because this greatly depends on your climate, riding conditions, type of oil used etc. For example a bike sitting in the garage for weeks, may end up with a dry air filter. 

Please feel free to contact us by email at mullermotorsport@ajty.cz if you have any questions.