Upgrading your KTM EXC with carbon fiber parts is one of the most rewarding modifications you can make. Not only do you gain a significant weight reduction — often 30–50% compared to OEM plastic — you also get a finish that stands out on the trail and on the podium. This guide walks you through everything you need to know before and during installation.
What You Need Before You Start
Gather the following tools: a T25 Torx driver, 4 mm and 5 mm Allen keys, a panel removal tool, and a soft cloth to protect the carbon surface. Have the original OEM parts nearby for reference.
Step 1 — Remove the OEM Plastic
Start with the bike cold and on a stand. Remove the seat if necessary to access the fairing mounting points. CS Compositi parts are designed as direct OEM replacements — every mounting tab, slot and screw hole matches the factory location exactly. No drilling, grinding or modification required.
Step 2 — Dry Fit First
Before fastening anything permanently, hold the carbon piece in position and verify all tabs seat correctly. On KTM EXC 250–690 models, the headlight mask clips onto two upper tabs and secures at the lower bracket — both should engage without force. If a part feels tight, check for debris in the mounting channel first.
Step 3 — Install with Original Hardware
Reuse your original factory bolts and clips. CS Compositi parts are manufactured to OEM tolerances, so all original fasteners fit perfectly. Tighten fairing screws to 2–3 Nm. Over-tightening can stress the material around mounting holes, so use a torque screwdriver if available.
Step 4 — Check Clearances
After installation, turn the bars lock-to-lock and confirm no carbon edge contacts any other component. The gap between the carbon and adjacent panels should be even and consistent with the factory gap. If you spot a contact point, 3 mm foam tape makes an ideal buffer.
Pro Tips
- Clean mounting areas with isopropyl alcohol before fitting — removes silicone and wax residue
- Apply UV-protective lacquer to exposed edges for long-term finish retention
- Keep your OEM plastic parts — returning the bike to stock is straightforward and good for resale
Installing CS Compositi carbon parts on a KTM EXC takes under 30 minutes and requires no special tools or modifications. The result is a lighter, sharper-looking machine built from the same aerospace prepreg carbon used in motorsport and aviation.