HB Crashbars and KTM factory CB tank guards

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by njyang, Apr 21, 2006.

  1. njyang

    njyang Been here awhile

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    Hi all,

    just got a set of HB crashbars from Andy, great service and all. However, I don't see how it is possible to mount the HB crashbars with the KTM factory carbon fiber tank guards at the same time.

    The bottom of the KTM guards took up some space that the bottom mounting point of the HB bars will not line up with the bottom mounting bolt of the gas tank.

    Anyone has any experience with this?

    If they can fit together at the same time, I have a set of KTM guards for sale:cry

    Thanks
    Joe
    #1
  2. Don Lemelin

    Don Lemelin Scuderia West

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    #2
  3. shardzero

    shardzero I have a bike.....

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    Is there any chance you can show images of the mounting of the HB guards. ie, the actual point where they mount onto the bike. Do they only mount to the lower tank and behind the upper tank??
    #3
  4. TipOver

    TipOver Been here awhile

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    The HB mounts to 3 points on each side. 1. To a crossbar fixed to the headlight mount assembly. 2. To the bottom of the tank. 3. To the crossbar that runs from side-to-side thru the vent holes in the tanks.

    It's a very rigid, very strong system.
    #4
  5. njyang

    njyang Been here awhile

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    Thanks for the info Don, did you have to cut the whole bottom size of the gurads off, or just trim the pug area a little?

    Shardzero
    I'll get some pixs when I attempt the installation again within the next day or so.
    #5
  6. Don Lemelin

    Don Lemelin Scuderia West

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    [​IMG]

    Cheers.
    #6
  7. njyang

    njyang Been here awhile

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    Thanks for the pix Don, I couldn't bear the thought of cutting up thus beautiful piece of carbon fiber, so unfortunately, the KTM guards are for sale. Plus, I didn't want to silicon on the factory paint job of the tanks.:D

    Here are some pixs of the KTM guards.]
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    This right guard has slight rash due to a tip over, but it isn't much at all as you can see in the pixs.
    [​IMG]
    [​IMG]
    #7
  8. njyang

    njyang Been here awhile

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    Ok, here's some pixs for the installation.

    All the nutz & bolts, and MHL to round off the edges:1drink
    [​IMG]

    Mounting points at the headlight assemble for the front cross bar, replace the factory nutz & bolts with longer M8 bolts.
    [​IMG]

    Front cross bar mounted, tabs at each end are the upper mounting points for the left and right bars.
    [​IMG]

    These two show another crossbar connecting the left bar to the right through that window between the radiator and airbox. A cover behind the fan on the left side has to be removed by taking off the left gas tank, the inner screw will come out, just be pationed and use the T and socket set from the KTM tool kit, push this hose connected to the airbox partly out of the way, and shine a flashlight to that inner dark spot, and you are good to proceed carefully. The fan cover has to be trimmed according to this instruction/template included with the crashbars.
    [​IMG]
    [​IMG]

    The bottom of both bars are mounting at the bottom bolts of the gas tanks, replace with included longer bolts.

    While losse fitted all the nutz & bolts, I noticed this clearance issue. After tiening different bolts in dfferent orders, the solution was to snug up the bolts at the front bars first, then all bolts on the right side, I found thiis will give me more clearance for the left side. When done, there is still less than a 1/4" gap at that spot. But I think this system is very rigid and will maintain the gap at any "easy and normal" spills:D
    [​IMG]
    #8
  9. njyang

    njyang Been here awhile

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  10. rpilottx

    rpilottx Long timer

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    I just went thru mounting carbon fiber tank guards on my 950S. I have the stock KTM crashbars on the bike as well. The tank guards were purchased from Adventurer's Workshop and go on with 4 bolts. They required enlarging the bottom holes by drilling out 2-3mm to get the bolts to align.

    You might want to give Andrew a call. The product is very heavy and very well made.
    #10
  11. BigDogAdventures

    BigDogAdventures Fart Letter

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    The fitment can be a little tricky---------take your time and when your done you will be so happy. These have got to be the strongest guards you could put on the bike.

    [​IMG]
    #11
  12. MymoJoe

    MymoJoe Ride Ride Ride

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    Did you sell your KTM Guards????? I am interested.

    Joe Morgan

    #12
  13. njyang

    njyang Been here awhile

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    Sorry Joe, I have actually installed the factory CB guards with the HB bars in place.

    As is, the bottom side of the factory CB guards will not fit in conjunction with the HB bars. Also, in addition to the bottom screws, sillicon was suppose to be used to glue the CB guards to the side of the tank, which I did not want to, due to the beautiful and "faster" orange paint:D .

    But since the sale didn't happen in these few months, I finally took a deep breath, cut and trim out the whole bottom side of the guards, and sillicon them to the tanks. The lowwer edges were trimmed just enough to clear the HB bars. The job actually came out looking quite good. But there were no screws used for mounting, just sillicon.

    I'll try to attach some pixs later on.
    #13
  14. njyang

    njyang Been here awhile

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    [​IMG]
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    #14
  15. njyang

    njyang Been here awhile

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    Holy crap, your 950 is laying eggs all over the place:eek1 :lol3

    #15
  16. Misery Goat

    Misery Goat Positating the negative Super Moderator

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    nice set up. :thumb
    #16
  17. motorjon68

    motorjon68 Been here awhile

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    Where do you get these higher HB guards. I can only find the lower ones.
    #17
  18. AFekete

    AFekete Long timer

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    Discontinued by Hepco Becker :(
    #18
  19. motorjon68

    motorjon68 Been here awhile

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    So what's my next best option?
    #19
  20. DSM8

    DSM8 Where fun goes to die....

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