Custom brake likes for High Fender mod on 04 "S" bike

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by lacofdfireman, Jun 19, 2013.

  1. lacofdfireman

    lacofdfireman Been here awhile

    Joined:
    Jan 29, 2008
    Oddometer:
    968
    Location:
    St. George, UT
    So last night I spent like 3hrs researching the High Fender mod and this is what I concluded. The 04 "S" bike is to tall to do this mod with stock brake lines. I think this would be especially true since I want to add 2" Rox risers to my handlebars. So my next question is has anyone ever had custom brake lines built and who does it best? Any idea on the length these lines would need to be for an 04 "S"? Hoping to get this done before the end of summer.
    Or is there a better way to do this mod without having to go custom that someone has done. Any info would be appreciated...
    #1
  2. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    697
    Location:
    Georgia
    Galfer USA will build you custom brake lines- put a tape measure on your existing lines, and add the extra length you require. You can specify the type of banjo you want. I think their braided stainless lines are very good compared to the new KTM lines. I have not priced Galfer custom lines, but I dont think they would be more than OEM prices.

    I have been looking at this same project for my 06 "S" model. I have ROX 1.75" Risers. While I like the most recent 990 brake line set up, out of laziness I may simply order another S brake line and install it down the right fork tube. The "S" length brake line is about $76

    This is the list I have been putting together:
    <style>table { }td { padding-top: 1px; padding-right: 1px; padding-left: 1px; color: black; font-size: 12pt; font-weight: 400; font-style: normal; text-decoration: none; font-family: Calibri,sans-serif; vertical-align: bottom; border: medium none; white-space: nowrap; }.xl63 { text-align: center; }.xl64 { font-weight: 700; text-align: center; }.xl65 { text-align: center; border: 0.5pt solid windowtext; }.xl66 { border: 0.5pt solid windowtext; }.xl67 { text-align: left; vertical-align: top; border: 0.5pt solid windowtext; }.xl68 { text-align: left; border: 0.5pt solid windowtext; }.xl69 { }.xl70 { border: 0.5pt solid windowtext; }.xl71 { color: red; text-align: center; border: 0.5pt solid windowtext; }.xl72 { text-align: right; border: 0.5pt solid windowtext; }.xl73 { text-align: right; border: 0.5pt solid windowtext; }.xl74 { font-weight: 700; text-align: center; border: 0.5pt solid windowtext; }.xl75 { font-weight: 700; text-align: center; border: 0.5pt solid windowtext; }</style> <table style="border-collapse: collapse;width:441pt" border="0" cellpadding="0" cellspacing="0" width="441"> <colgroup><col style="mso-width-source:userset;mso-width-alt:6101;width:143pt" width="143"> <col style="width:65pt" width="65"> <col style="mso-width-source:userset;mso-width-alt:7552;width:177pt" width="177"> <col style="mso-width-source:userset;mso-width-alt:2389;width:56pt" width="56"> </colgroup><tbody><tr style="height:15.0pt" height="15"> <td class="xl74" style="height:15.0pt;width:143pt" height="15" width="143">KTM Code</td> <td class="xl74" style="border-left:none;width:65pt" width="65">QTY</td> <td class="xl74" style="border-left:none;width:177pt" width="177">Description</td> <td class="xl75" style="border-left:none;width:56pt" width="56">Price</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">42013226000</td> <td class="xl65" style="border-top:none;border-left:none">7</td> <td class="xl68" style="border-top:none;border-left:none">copper washer 10x16x1</td> <td class="xl72" style="border-top:none;border-left:none">
    </td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl71" style="height:15.0pt;border-top:none" height="15">60013025100</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">Brake hose guide front</td> <td class="xl72" style="border-top:none;border-left:none">$5.17</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">60013025050</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">Rubber for brake hose guide</td> <td class="xl72" style="border-top:none;border-left:none">$1.10</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">150800163</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">Collar Screw M8 x 16</td> <td class="xl72" style="border-top:none;border-left:none">
    </td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">60013012200</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl67" style="border-top:none;border-left:none">Brake Hose Front ADV S</td> <td class="xl72" style="border-top:none;border-left:none">$76.32</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">60008019000</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">Brake Hose Guide Lower</td> <td class="xl72" style="border-top:none;border-left:none">$3.78</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">60001079000</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">Brake Hose Guide Top</td> <td class="xl72" style="border-top:none;border-left:none">$3.22</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">6300801000004</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">FENDER FRONT ORANGE 06</td> <td class="xl72" style="border-top:none;border-left:none">$33.97</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">0014060203</td> <td class="xl65" style="border-top:none;border-left:none">4</td> <td class="xl66" style="border-top:none;border-left:none">HH COLLAR SCREW M 6X20 WS=8</td> <td class="xl72" style="border-top:none;border-left:none">$1.35</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">58408009050</td> <td class="xl65" style="border-top:none;border-left:none">4</td> <td class="xl66" style="border-top:none;border-left:none">SPACER BUSHING FRONT FENDER</td> <td class="xl72" style="border-top:none;border-left:none">$1.69</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl71" style="height:15.0pt;border-top:none" height="15">47001094000X4</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">FORK PROTECTOR L/S+R/S 85SX 06</td> <td class="xl72" style="border-top:none;border-left:none">$18.59</td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15">59001092050</td> <td class="xl65" style="border-top:none;border-left:none">6</td> <td class="xl68" style="border-top:none;border-left:none">SPECIAL SCREW M6X12,5 WS=8</td> <td class="xl73" style="border-top:none;border-left:none">$0.93 </td> </tr> <tr style="height:15.0pt" height="15"> <td class="xl65" style="height:15.0pt;border-top:none" height="15"> UFO 112720</td> <td class="xl65" style="border-top:none;border-left:none">1</td> <td class="xl68" style="border-top:none;border-left:none">FORK PROTECTOR L/S+R/S 85SX 06</td> <td class="xl70" style="border-top:none;border-left:none">Orange</td> </tr> </tbody></table>
    <style>table { }td { padding-top: 1px; padding-right: 1px; padding-left: 1px; color: black; font-size: 12pt; font-weight: 400; font-style: normal; text-decoration: none; font-family: Calibri,sans-serif; vertical-align: bottom; border: medium none; white-space: nowrap; }.xl63 { text-align: center; }.xl64 { font-weight: 700; text-align: center; }.xl65 { text-align: center; border: 0.5pt solid windowtext; }.xl66 { border: 0.5pt solid windowtext; }.xl67 { text-align: left; vertical-align: top; border: 0.5pt solid windowtext; }.xl68 { text-align: left; border: 0.5pt solid windowtext; }.xl69 { }.xl70 { border: 0.5pt solid windowtext; }.xl71 { color: red; text-align: center; border: 0.5pt solid windowtext; }.xl72 { text-align: right; border: 0.5pt solid windowtext; }.xl73 { text-align: right; border: 0.5pt solid windowtext; }.xl74 { font-weight: 700; text-align: center; border: 0.5pt solid windowtext; }.xl75 { font-weight: 700; text-align: center; border: 0.5pt solid windowtex</style> <table style="border-collapse: collapse;" border="0" cellpadding="0" cellspacing="0" height="323" width="345"> <colgroup><col style="mso-width-source:userset;mso-width-alt:6101;width:143pt" width="143"> <col style="width:65pt" width="65"> <col style="mso-width-source:userset;mso-width-alt:7552;width:177pt" width="177"> <col style="mso-width-source:userset;mso-width-alt:2389;width:56pt" width="56"> <col style="width:65pt" width="65"> </colgroup><tbody><tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr><tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr><tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> <tr style="height:15.0pt" height="15"> </tr> </tbody></table>
    #2
  3. brents347

    brents347 Trusting my Cape...

    Joined:
    Mar 5, 2006
    Oddometer:
    4,332
    Location:
    Where the hell is Truckee, CA?
    I don't think I understand. I had on 04 'S', and ran high fenders. What is the difference between high and low fender as far as the brake line is concerned?

    Brent
    #3
  4. Sumi

    Sumi Long timer

    Joined:
    Mar 30, 2010
    Oddometer:
    1,895
    Location:
    Hungary
    I have a 2005.5 (lowest - 210mm) model converted to a 2004S (highest - 265mm), and have 2" risers + use the stock (2005.5) brake line and the brake line that came with the TT high fender kit - without any problem with high fender.

    [​IMG]
    #4
  5. 950trailrider

    950trailrider Adventurer

    Joined:
    Mar 18, 2007
    Oddometer:
    22
    I think the OP was maybe referring to the standard brake lines (from the newer models with the 2 individual brake lines) being too short to be used on the 04 S model. I am interested in this same scenario, being able to convert to a high fender and getting rid of the cross-over brake line.
    Pyndon fabricated up a T-split tube, one brake line coming in from the master brake cylinder and 2 individual brake lines going out the calipers. Mounted to the bottom triple clamp. Isn't the latest R model as tall as the original o4 "S"?
    #5
  6. Sumi

    Sumi Long timer

    Joined:
    Mar 30, 2010
    Oddometer:
    1,895
    Location:
    Hungary
    990S (all years) and 2009R(if there is such in the US), 2010 R are also 265mm
    #6
  7. Off Road Ryder

    Off Road Ryder Long timer

    Joined:
    Mar 29, 2010
    Oddometer:
    3,134
    Location:
    Kent Wa
    On My 06 S Pretty much the same as your 04.
    I purchased a KTM 450 fender and then obtained a long Spiegler brake line PN EL-1054-000-006
    remove the cross over brake line and switch the bottom double banjo bolt to the top where the old and new brake lines will connect. Super easy.
    No need for a kit.:clap
    #7
  8. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    697
    Location:
    Georgia
  9. 950trailrider

    950trailrider Adventurer

    Joined:
    Mar 18, 2007
    Oddometer:
    22
    Not to argue but as far as I know there was a difference between the 2004 "S" suspension travel vs the later models

    Adventure = 230mm travel
    2003 Adventure 'S' = 265mm travel
    2004 Adventure = 230mm travel
    2004 Adventure 'S' = 265mm travel
    2005 Adventure = 210mm travel
    2005 Adventure 'S' = 245mm travel
    2006 Adventure = 210mm travel
    2006 Adventure 'S' = 245mm travel
    #9
  10. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    697
    Location:
    Georgia
    I'm looking at making the right side brake line a little shorter than the left- to avoid the extra loop up near the handle bars. To check the price of custom lines against KTM I looked through the fiche from 04 to 2010- I found some interesting ( to me) data:

    In 2004 the parts fiche lists two different brake line lengths:

    • 1284mm ( 50") for the Adv S model
    • 1249mm (49") for the Adv model
    In 2006 the parts fiche gives no length for the S model or Std model.



    In 2007-2010 the parts fiche lists the front brake line as 1320mm (52")


    So even though the suspension travel on the 04's is longer than subsequent years- the front brake line seemed to be the shortest.


    Thinking that the 49" line is the one to use- ktm 60013012100 $76
    #10
  11. tahoeacr

    tahoeacr Long timer

    Joined:
    Jan 7, 2007
    Oddometer:
    2,220
    Location:
    Lake Tahoe
    Hey now, don't forget the 07 S. 265mm for us too!
    I had one made when I went to single disk. Seems like the $75 figure mentioned earlier stands in my mind. I got to choose the color of the hose and the anadizing of the ends.

    [​IMG]
    #11
  12. lacofdfireman

    lacofdfireman Been here awhile

    Joined:
    Jan 29, 2008
    Oddometer:
    968
    Location:
    St. George, UT
    This is probably a dumb question but I am not with my bike at the moment but couldn't you just use the Double banjo at the Master cylinder instead of the left brake caliper then run a new single banjo on both ends from the Right caliper to the double up at the master? Would this work? Does it even make sense? I am not with my bike right now so I am only picturing this in my mind. But seems like it should work..
    #12
  13. brents347

    brents347 Trusting my Cape...

    Joined:
    Mar 5, 2006
    Oddometer:
    4,332
    Location:
    Where the hell is Truckee, CA?
    Yes. This is how it was always done before the 990 with its brake line set-up. You just buy a second front brake line and swap the banjo bolts as you said. The only down side is the right side brake line has a funky loop at the master cylinder so that it has a proper way to expand as the suspension compresses.
    #13
  14. lacofdfireman

    lacofdfireman Been here awhile

    Joined:
    Jan 29, 2008
    Oddometer:
    968
    Location:
    St. George, UT
    I figured with the taller suspension of the 04 'S" and that I will be putting on 2" Rox Risers maybe that loop won't be as much as an issue. What do you think?
    #14
  15. brents347

    brents347 Trusting my Cape...

    Joined:
    Mar 5, 2006
    Oddometer:
    4,332
    Location:
    Where the hell is Truckee, CA?
    I think the loop needs to be there. Partly also because the new extra brake line is too long (because it doesn't run over to the left fork leg) so the loop takes up the slack.
    #15
  16. Off Road Ryder

    Off Road Ryder Long timer

    Joined:
    Mar 29, 2010
    Oddometer:
    3,134
    Location:
    Kent Wa
    I dont have a loop in mine. It is race tested:wink:
    I tried to find a photo that showed the master, This is the best I could find.
    [​IMG]

    [​IMG]
    #16