990 High Fender Mod Question... Brake Lines?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Garand, Dec 26, 2007.

  1. Masa

    Masa Been here awhile

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    Put fork protectors on, from '06 85sx, part #47001094000X4. The "high fender" is modified from a dead stock low fender.

    Did my little best to elongate the holes with a heat gun and screw driver, but didn't quite make it, good enough tho.. Routed the ABS sensor cable inside guard, thinking there's enough room even if forks bottom (not very likely with my skills).

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  2. RozzyCat

    RozzyCat Bleeds orange

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  3. alpo996

    alpo996 Adventurer

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    Nice ice studs, Masa! What brand are they, and do they screw in?
  4. Masa

    Masa Been here awhile

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  5. alshaffer

    alshaffer Adventurer

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    After reading through the entire thread, and reviewing the HOW Parts List, my only question is in regards to the Fork Protectors. A lot of discussion about modifying the 85SX protectors (47001094000X4 Orange, 4700109400030 Black) to properly fit the 990Adv forks, but can anyone weigh-in on use of the "KTM Fork Protectors L & R)" (5900109400004 Orange, 5900109400030 Black)? An inmate included these in his parts list early in this thread, but I didn't see much follow-on discussion.

    Anyone have any info on these?
  6. Masa

    Masa Been here awhile

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  7. Lycan1

    Lycan1 Grizzly herder

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    Recently I had a question about this modification. I shot some better pictures as well as scanned my invoices that have the list of parts for the job (as I did it). Hopefully this will be helpful to someone doing this. I have had zero issues with water spray after doing this and no air flow problems either. If you use spacers like I did to lower the fender below the triple clamp,( rather than raise the brake line harness that is attached to the top side of the lower triple as one rider did) you may have contact with the tire under full compression (at the rear most part of the fender). You could trim the fender, or simply adjust your suspension settings as I did. Also IF you use spacers you will need 30mm bolts to come up through the fender (and spacers) into the bolt holes in the lower triple. I used 4 stainless washers not listed on the invoice as well.

    Here are the parts:

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    Here are shots of the brackets I made to reinforce the fork protectors since the holes do not line up (one out of three does). This is 3/4" by 1/4" aluminum from the hardware store.

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    I made this side longer on the side to attach the abs line with a zip tie.

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    I trimmed the stock clip off the abs bracket and trimmed the fork protector to fit around what was left.

    Since this was originally a thread about Brake Line Routing with a High Fender I have included shots of how I routed mine without disturbing my stock brake line harness. For reference I have a 2009 with ABS.

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    Thats it. It wasn't a difficult job. I made the brackets at the bottom of the fork protectors by measuring the front and sides and using a vise and a hammer to bend the material. Then filed the edges with a big flat file. The insides of the forks will get rubbed by the brake lines, and I used 3M clear film to prevent any more damage after I noticed the anodization being rubbed off (visible in one of the shots).
  8. plumbtired

    plumbtired plunging into the farkle

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    Might want to consider routing the brake lines outside the forks. Didn't theses bikes required pipe fittings? :lol3
  9. Lycan1

    Lycan1 Grizzly herder

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    :rofl

    Cheap, fast fix that was done because I had a 2 week bike holiday starting the morning after the other parts came in. It works so I left it alone. Don't fix it if it ain't broke.

    The lines work very well where they are (other than the fork contact) and are less likely to snag in a crash IMO. Others have routed on the outside and still had the rubbing issue. Once you put on the clear tape it really isn't an issue.
  10. Brown Town

    Brown Town Been here awhile

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    Is there a left side break hose guide as well or just the right side?
  11. JoeMongo

    JoeMongo ¿Por dónde?

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    Same part. Just buy two of each.
  12. Brown Town

    Brown Town Been here awhile

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    But then it's facing the wrong way (in instead of out).

    Just bend it to shape?:huh
  13. Lycan1

    Lycan1 Grizzly herder

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    Post # 107 third and forth pictures. No need to bend anything, they work fine as is.
  14. Brown Town

    Brown Town Been here awhile

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    It doesn't push your lines towards your tire too much? Man just holding it up to mine and it looks sketchy without some modding.
  15. Lycan1

    Lycan1 Grizzly herder

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    65,000 kms. On it with zero issues now. Even in mud so bad my wheel was nearly locked and no problems. On the side where the opening faces the tire I cinched a zip tie to tighten the wire opening, preventing the rubber insert from pulling out.
  16. Brown Town

    Brown Town Been here awhile

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    I just bent it slightly in the opposite direction and it's now similar to the right side in distance from the tire.

    The zip tie is a great idea–almost mandatory.

    Thanks for the help!:clap
  17. DIRT DERRICK

    DIRT DERRICK Adventurer

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    Zen Overland has started doing kits, Mine was a prototype but I think it looks Spot on!
    I will post some pics tomorrow!
  18. Deathb4Mullets

    Deathb4Mullets n00b

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    Any word on the kits?
  19. kleinholz

    kleinholz Adventurer

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    Hi folks,

    I searched an eternity for a bracket for the fork guards. Fortunately Zen Overland finally came up with a great looking solution I really like. :clap (Pictures to be found below or on the net, search for "Zen Overland High Fender Kit")

    Only problem is, my bike is a 2012 ABS model and Gabriel told me their brackets won´t fit ABS bikes because of the sensor mount. :cry

    He would give it a go to design them for our bikes too but needs a bike as a template to do all the measuring.

    He could design brackets fitting the SX85 protectors and the closed ones from the 690 Enduro I believe.

    I´m living in Austria so it´s not possible to borrow them my bike but if there´s anyone out there living near them it would be great if you could help! I´m sure Gabe would have some nice reward for you :D

    Really like dealing with them (not affiliated in any way). Gabe guided me through the whole decision process for the Kriega soft luggage. I couldn´t decide between the US30 or the US20 and also needed a backpack. He put everything I needed for my daily commute in the pockets to figure out which would fit best! Great guy!

    You could be our all hero if anyone of you could make this possible!

    Regards
    Kleinholz
  20. Zen Overland

    Zen Overland Adventurer

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    Machined from aluminium angle. The bolts that go into the fork leg are countersunk so the plastic fork guards sit flush, and the holes for the fork guard are tapped.

    We also made replacement spacers to go under the fender, to pack it away from the triple clamps a bit. Like the stock KTM spacers but with another 10mm or so clearance.

    The project we did was for a non ABS bike, but it would be great to make a kit for the ABS version.

    We have these brackets in stock if anyone needs them.