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Old 01-28-2011, 06:48 AM   #4336
tbarstow
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Low Fender

It doesn't look too bad in blue:



I took Hotmamandme's suggestion and just riveted the KTM fender to the fork protectors. To keep the headlight from flopping around, I took a piece of aluminum treadplate, cut and bent it into a box. The HID power supplies go in there.
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Old 01-28-2011, 06:51 AM   #4337
DiscoDino
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Quote:
Originally Posted by tbarstow View Post
It doesn't look too bad in blue:



I took Hotmamandme's suggestion and just riveted the KTM fender to the fork protectors. To keep the headlight from flopping around, I took a piece of aluminum treadplate, cut and bent it into a box. The HID power supplies go in there.
Does it move any? Did you mount the rear of the fender or only the rivets hold it in place?
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Old 01-28-2011, 07:30 AM   #4338
AviatorTroy
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Guys there's a used Staintune exhaust for $350 over on IBMWR classifieds right now.

Now, does anyone know what the seat height is on these X-Challenges? Thanks......
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Old 01-28-2011, 07:56 AM   #4339
Hotmamaandme
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Good job

Looks like you put 4 rivets per fork side, not a bad idea. I only have two each side. I havent had any issues with it getting loose but a couple extra rivets wouldnt hurt. So what did you do with the rear fender supports?

I like the little box for the stock head light support. It holds HID ballast as well super! removing the stock high fender wich supports the bottom of the stock head light was some thing i hadnt really solved other than some zip ties. Good job.

Quote:
Originally Posted by tbarstow View Post
It doesn't look too bad in blue:



I took Hotmamandme's suggestion and just riveted the KTM fender to the fork protectors. To keep the headlight from flopping around, I took a piece of aluminum treadplate, cut and bent it into a box. The HID power supplies go in there.
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Old 01-28-2011, 08:14 AM   #4340
mike,p
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Quote:
Originally Posted by Hotmamaandme View Post
Looks like you put 4 rivets per fork side, not a bad idea. I only have two each side. I havent had any issues with it getting loose but a couple extra rivets wouldnt hurt. So what did you do with the rear fender supports?

I like the little box for the stock head light support. It holds HID ballast as well super! removing the stock high fender wich supports the bottom of the stock head light was some thing i hadnt really solved other than some zip ties. Good job.
Nice Job !!!
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Old 01-28-2011, 08:42 AM   #4341
AZ-Twin
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Quote:
Originally Posted by tbarstow View Post
It doesn't look too bad in blue:



I took Hotmamandme's suggestion and just riveted the KTM fender to the fork protectors. To keep the headlight from flopping around, I took a piece of aluminum treadplate, cut and bent it into a box. The HID power supplies go in there.
Tbarstow,

That looks good. How far do the rivets protrude through the back of the OEM fork guard? Is there any chance of them hitting the fork and scratching the tube, or slider under compression?
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Sierra Vista AZ to Paonia CO and Back through Moab UT

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Old 01-28-2011, 08:55 AM   #4342
tbarstow
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Quote:
Originally Posted by DiscoDino View Post
Does it move any? Did you mount the rear of the fender or only the rivets hold it in place?
The rear is just zip tied to to a couple of holes in the fork protector.

I'm going to ride it to Vegas tonight, so I'll find out if it moves at all.
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Old 01-28-2011, 09:10 AM   #4343
DiscoDino
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Quote:
Originally Posted by tbarstow View Post
The rear is just zip tied to to a couple of holes in the fork protector.

I'm going to ride it to Vegas tonight, so I'll find out if it moves at all.
Sweet - eager to find out how it holds!

Cheers,
Nadim
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Old 01-29-2011, 12:03 AM   #4344
snooker
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Originally Posted by Geoffster View Post
This is why I sold my LV and went back to stock. The few pipes that fit as well as stock are expensive! (Akrapovic and another that I can't recall.)

BUT If I did a ton of off-roading (like many XChallenge riders), I'd say "F*ck the expensive beer and call drinks for a couple of weeks -- I'm getting an Akrapovic that won't sear my coolant hose AND LEAVE ME STRANDED."
Geoff - dude - I thot you always went for simple and practical solutions?

Here's what I did in about an hour for $.20:
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Old 01-29-2011, 06:32 AM   #4345
AZ-Twin
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I like that solution Snooker. I had thought about drilling a hole in my HB mount and attaching the muffler mount to it, but I didn't want to put all that weight on the two little 6mm bolts that hold the racks on. Your solution still supports the mufler with the big bolt, and just keeps it from rotating by hooking it to the rack.

I am going to build a bracket like Cruz suggested, and incorporate some type of retainer like you have, and that should take care of any issues with the muffler moving around and stressing the header, or getting too close to my hose.

I will take notes and pics when I build the bracket so if it works, it can be reproduced easily.
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I'm not real fast, but I do have a dog named Dakar!
97 M900, 07 G650 XChallenge,11 KTM 990 ADV R
2011 North up the CDR
Sierra Vista AZ to Paonia CO and Back through Moab UT

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Old 01-29-2011, 08:44 AM   #4346
Geoffster
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Quote:
Originally Posted by snooker View Post
Geoff - dude - I thot you always went for simple and practical solutions?

Here's what I did in about an hour for $.20:
With all respect, your solution still balances the mass between the exhaust studs and the rear hanger. I'd prefer to have the muffler supported at two points (as intended) and have the studs going along for the ride.
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Old 01-29-2011, 03:02 PM   #4347
AZ-Twin
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Quote:
Originally Posted by Cruz View Post
Have you thought about taking the LV to a muffler shop and get them to make a bracket similar to the oem one so that it slips on to the frame pin and supports it and the header?
Not until you mentioned it, no.

So today I was supposed to go for a ride, but I got the days mixed up and thought my wife was taking her sister to the airport on Sunday, but it was today, so my boy and I spent the day in the shop. Better than riding, and I got something done you may be interested in.




So I started out with a piece os 1 & 1/2" round tube, a big rubber plug I got at Ace Hardware, some 3/4" square tube, some 1/2" flat stock, and a hose clamp.



I welded the square tube to the side if the round tube before I made the bushing.





I had a hell of a time getting the rubber plug into the tube.







After I get the rubber grommet in, I drilled a 15/32 hole in it as that is what the pin measured, then after a couple measurements and some cutting and grinding I had this.



I had planned to weld a piece of the pipe pictured earlier to it but I didn't have much room, so I just used a piece of flat stock. Here is the finished product. I still need to paint it.




















The pipe feels really solid, and is not close to the hose, so I will keep an eye on it, I need to go on a ride tomorrow to test some things.
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Rob Swartzwelder, Southern AZ
I'm not real fast, but I do have a dog named Dakar!
97 M900, 07 G650 XChallenge,11 KTM 990 ADV R
2011 North up the CDR
Sierra Vista AZ to Paonia CO and Back through Moab UT

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Old 01-29-2011, 05:04 PM   #4348
darrendeep6
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Quote:
Originally Posted by AZ-Twin View Post
Not until you mentioned it, no.

So today I was supposed to go for a ride, but I got the days mixed up and thought my wife was taking her sister to the airport on Sunday, but it was today, so my boy and I spent the day in the shop. Better than riding, and I got something done you may be interested in.




So I started out with a piece os 1 & 1/2" round tube, a big rubber plug I got at Ace Hardware, some 3/4" square tube, some 1/2" flat stock, and a hose clamp.



I welded the square tube to the side if the round tube before I made the bushing.





I had a hell of a time getting the rubber plug into the tube.







After I get the rubber grommet in, I drilled a 15/32 hole in it as that is what the pin measured, then after a couple measurements and some cutting and grinding I had this.



I had planned to weld a piece of the pipe pictured earlier to it but I didn't have much room, so I just used a piece of flat stock. Here is the finished product. I still need to paint it.




















The pipe feels really solid, and is not close to the hose, so I will keep an eye on it, I need to go on a ride tomorrow to test some things.
Please excuse my noobniss, but is the reason you didn't weld it is because the link pipe is Ti?
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Old 01-29-2011, 05:50 PM   #4349
AZ-Twin
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Originally Posted by darrendeep6 View Post
Please excuse my noobniss, but is the reason you didn't weld it is because the link pipe is Ti?
I don't know what the pipe is made of. So that is part of why I didn't weld it.

I think, since the mission of the bracket is to hold the pipe up, it is fine just clamping it, as for the pipe to go down it would have to compress the mount, or the pipe would have to push outward away from the bike. Given the way it is all put together I am pretty sure this will work.

If I have an issue with it moving around I might drill it and put a screw through the bracket into the pipe, but I don't think that will be necessary.
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Rob Swartzwelder, Southern AZ
I'm not real fast, but I do have a dog named Dakar!
97 M900, 07 G650 XChallenge,11 KTM 990 ADV R
2011 North up the CDR
Sierra Vista AZ to Paonia CO and Back through Moab UT

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Old 01-29-2011, 06:25 PM   #4350
Cruz
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So, about the suspension and the Power Commander???
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