Dirtinblood Riser Install

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Holaday, Apr 3, 2009.

  1. Holaday

    Holaday Man of Leisure

    Joined:
    Sep 4, 2006
    Oddometer:
    635
    Location:
    Vancouver's North Shore, B.C.
    Well the riding weather is fast approaching here in BC so its time to start getting the new ride ready. I bought this 990S last fall on my way to Baja when my GSPD's driveshaft blew. I've been putting the PD back together and I'm waiting for the driveshaft to come back from Bruno's. So I turned my attention to the KTM. I wanted the bars up higher and after a quick search here I decided to go with Dirtinblood's Bone 2" riser.


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    Handlebar off my A.D.D. kicked in and I didn't tie the bar off which I should of but I wanted to move on to more interesting things.

    I discovered that the bolts were binding in the riser so I had to go the shop at work and turn the bolts on a lathe so they would turn freely in the riser.

    [​IMG]

    Bolts trimmed down a little. The bolts were binding in the riser just below the head of the bolt.


    Riser and bar support mounted. The bolts that are supplied to mount the bar support to the riser require a 7 mm allen key WTF. I can't believe I actually own one but it was not with me so I had to drive home and get it.


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    Bars on


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    The front brake line is just long enough. I actually think its a little too tight but it will do for now. Does anyone make a longer one ?

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    Front brake line holder

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    Cables all tidied up



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    Finished. Except for the issue with the bolts an easy upgrade. G2 throttle cam next.
    #1
  2. AUS CRUZER

    AUS CRUZER Lets Cruz

    Joined:
    Feb 9, 2008
    Oddometer:
    2,409
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    Geelong
    You will love them risers.Ive got a pair.They make the bike a different animal for taller blokes:wave :D
    #2
  3. AZcacti

    AZcacti Dope on a Rope

    Joined:
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    Phoenix, Arizona
    +1 from a taller Bloke:thumb
    #3
  4. DakarBlues

    DakarBlues One-everythinged man

    Joined:
    Dec 12, 2005
    Oddometer:
    1,303
    Location:
    The pink lake less circled
    Discovered that combining DirtinBlood riser and Small cruiser AIrhawk, you achieved the relaxation of a Pullman over long distance trips.
    COvered 800 miles in one sitting without any leg cramp or butt burn whatsoever.
    I had a bit of shoulder cramp though.
    Will try to get a cruise control Kaoko type or Penny tech (o-ring) before my next trip (St-Louis, MO <--> Dallas, TX) in June.
    I hope to get a rear MEFO Explorer by then, I already have the front, it works wonders.
    #4
  5. Big Tall Bastard

    Big Tall Bastard Voice of Reason

    Joined:
    Jun 11, 2008
    Oddometer:
    379
    Location:
    Vantucky, WA
    I rode the Desert 100 Dualsport loop last Saturday on my 990. The dualsport ride was about 150 miles. I have the 2" riser on it and probably stood on the pegs for 2/3rds of the ride. I'm 6'6" and could not believe the level of comfort. First bike that ever really fit me.! I also replaced the pegs with the KTM adjustable units.
    I cut a 1/4 inch off the end of my bars to deal with the cable length issue. Kevin said they would fit but it seemed tight and I was afraid of of yanking something loose. A tall seat is next.
    #5
  6. Holaday

    Holaday Man of Leisure

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    Vancouver's North Shore, B.C.
    Ya I really like the new set up, can't wait to try it out. I also removed the rubber pads on the foot pegs which gives a little more leg room. I don't like how tight the front brakeline is but I don't want to lose any width on the bars. I will keep my eyes out for a longer brakeline. Maybe TT has one ?
    #6
  7. Big Tall Bastard

    Big Tall Bastard Voice of Reason

    Joined:
    Jun 11, 2008
    Oddometer:
    379
    Location:
    Vantucky, WA
    The 1/4" per side didn't really mess with the leverage but I wouldn't cut off anymore than that. God these bikes Rock!
    #7
  8. barkbuster67

    barkbuster67 Adventurer

    Joined:
    Aug 14, 2007
    Oddometer:
    69
    Location:
    Upper MI
    +1 on the 2" riser. Excellent for the tall folks.
    +1 on the WTF with the 7mm hex. I haven't found one yet. Not even a torx will fit. Ended up using lots of loctite with the biggest flat blade and a wrench I could find.
    #8
  9. Holaday

    Holaday Man of Leisure

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    Vancouver's North Shore, B.C.
    Screwdriver and locktite... Dude thats scary!!! Mine is a cheap socket with a 7mm coming out if you know what I mean.. Try finding one of those at an auto parts store.
    #9
  10. barkbuster67

    barkbuster67 Adventurer

    Joined:
    Aug 14, 2007
    Oddometer:
    69
    Location:
    Upper MI
    You'd have to see the screwdriver to know what I mean:evil . 7mm in this town just ain't happening. That must be a normal size in Canada? I'll check in with the guys that work on our 4 wheel type transportation.
    #10
  11. Holaday

    Holaday Man of Leisure

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    Not a normal size in Canada either. When a 6 mm was too small and a 8 mm too big I thought it was a SAE bolt. Hell maybe it is.. The 7 mm socket was the first thing I found. Might be a left over from working on Datsun 510's in the eighties. :lol3
    #11
  12. dlh62c

    dlh62c Long timer

    Joined:
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    Oddometer:
    1,603
    Looks good. Can these work on an 07 640 Adventure?

    Is there a link to them somewhere?

    thanx

    daryl
    #12
  13. Holaday

    Holaday Man of Leisure

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    Pretty sure it will fit your 640. The best way to get your hands on one is to e-mail Kevin at ralleyconnex@gmail.com
    #13
  14. Jman

    Jman a.k.a. FUglyK

    Joined:
    Aug 27, 2003
    Oddometer:
    923
    Location:
    Land of Flat and Straight EH !
    Do most people have the issue with the bolts? I would love a set but don't have access to machinery that would turn the bolts down as described.
    #14
  15. Holaday

    Holaday Man of Leisure

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    Vancouver's North Shore, B.C.
    Spoke with Kevin at ralleyconnex he has never heard of this problem before and he says that he has sold about 200 of them. He thinks that the anodizing could have been a little heavy in the bolt holes or that the 07 bolts are a little thicker. It was an easy fix maybe just sanding the bolts might be enough but they were totally binding in the riser beforehand.
    #15
  16. Big Tall Bastard

    Big Tall Bastard Voice of Reason

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    I didn't have a problem with the bolts, fit right in. The anodizing makes sense.
    #16
  17. dlh62c

    dlh62c Long timer

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    Jan 11, 2006
    Oddometer:
    1,603
    Thanx

    Just ordered the 2" Rally Risers using PayPal.

    daryl
    #17
  18. rob748

    rob748 resident alien !!!!

    Joined:
    Jan 17, 2005
    Oddometer:
    825
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    traveling somewhere :)
    the one thing l noticed was on the first ones it had a rectangle linking the two sides together but the one l have has the round piece linking the sides together, it allows it to twist when you go down, l had to put it in a press to get it back
    #18
  19. Weldit

    Weldit Been here awhile

    Joined:
    Nov 4, 2009
    Oddometer:
    336
    Location:
    Muskoka Ontario Canada
    just installed my rally risers and no sign of a 7 mm allen wrench in my pile of tools
    was about to grind down a 8 mm a tad as no imperial was close either
    then tried a torx and a 45 is a pretty good fit and good enough for the 15-20 ft-lbs torque
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    should be a lot better now - for standing - I'm 6'8"
    my brake line is a bit tight on the radius down from master
    I switched the lines in the clip on frame behind gas tank (line to lever on top now)
    my bike has ABS so line goes back to ABS unit under seat
    ---------------------------------------------------------------------------------
    had to move throttle under bars - no room for rubber dust boot as it is to tight to switch gear now
    looks like you left boot on in your picture - any trick ?
    #19
  20. Holaday

    Holaday Man of Leisure

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    Vancouver's North Shore, B.C.
    ---------------------------------------------------------------------------------
    had to move throttle under bars - no room for rubber dust boot as it is to tight to switch gear now
    looks like you left boot on in your picture - any trick ?[/QUOTE]




    It's been so long I don't remember. I don't remember having any trouble with it. Try loosening the switch and rotating it out of the way. Then get your throttle in place. Maybe a little light grease or lube on the rubber boot and then rotate the switch back into place. Good luck.
    #20