High Fender Conversion

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Nightstalker, Jul 30, 2005.

  1. Nightstalker

    Nightstalker YO BUDDYPAL!

    Joined:
    Aug 5, 2003
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    6,011
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    Sunny Phoenix, AZ
    I did the high fender install today, keeping both disks. I hope these pictures can help anyone else planning to do this in the future.

    I used all KTM parts, supermoto fender, SX85 fork guards, an additional left side brake hose, and hose braket and grommet.

    Removing the stock low fender and crossover brake hose is easy enough. Make sure you have something to catch the brake fluid in, as it will all pour out with gravity's assistance. You'll want to pull the single banjo bolt from the brake master cylinder and swap it with the double banjo bolt from the left side caliber. Install the new long brake hose up the right hand side as pictured below.

    [​IMG]

    I had to modify the new brake hose bracket to fit the right side. A little cutting and bending and it was good to go. There's no hole in the caliber braket to install this on the right side, so I used the low fender mounting hole.

    [​IMG]
    [​IMG]

    Now you're ready to bleed the system. Lots of brake fluid and patience will go a long way.

    I had to cut a notch out of the rear mounting hole of the fork protectors. Also, I took a rat tail file to the front holes, the spacing is just a little off. I wire tied the hoses to the fork protectors. There's probably a better way to secure the hoses to the fork guards, I would like to know what everyone else used.

    [​IMG]

    I also need to fabricate two hose guides, one for at the fender, and one for at the top triple clamp. I have some wire ties at the top triple clamp keeping the hose in place, but I would like something that looks more factory.

    Here's some shots of the finished project. Good luck with yours!

    [​IMG]
    [​IMG]
    #1
  2. RedFlash

    RedFlash Go Cubs!

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    ...for the pics!

    Looks great. I'm goin' there next week!
    #2
  3. osteo

    osteo Motion is Life

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    diddo what RedFlash said, I'm doing mine in the next week or so as well!
    D
    #3
  4. K2m

    K2m ....58....

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    The high SM fender looks great. Whats it like in the rain?

    Where does one get the Dakar sticker from?

    Thanks.....
    #4
  5. 02Silver

    02Silver Been here awhile

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    Apr 29, 2004
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    K2M,

    http://www.advrider.com/forums/showthread.php?t=87666

    I ordered the black reflective to go on my black bike as well as some others. Once they come in this week, I'll post a picture.


    Stalker,

    Thanks for the high fender post. I may do it as well. I've read a lot of the how to's and completed pictures but yours has the best pictures that I've found so far.
    #5
  6. rvdcolf

    rvdcolf rvdcolf

    Joined:
    Jul 13, 2004
    Oddometer:
    36
    Location:
    Windhoek, Namibia
    Had a nice fall last weekend - stone got stuck in between tyre and this ridiculously LOW fender on 950, had a front wheel "lock-up" and there she goes! I really cannot understand the idea behind the factory-fitted low fender. Actually very dangerous in mud/stony areas. How long will it take for KTM to realise that?
    #6
  7. BLUE(UK)

    BLUE(UK) Long timer

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    Dec 2, 2004
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    3,423
    I think ur lying dude..............surely this could not and would not happen!!:huh
    The fender woulda broken off first..................was it a stone or a BIG lump of sludge???:eek1
    #7
  8. K2m

    K2m ....58....

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    Sydney Australia
    The problem BLUE(UK) is the braided brake line. It catches the stone and down you come. The solution is to fit the second line with what-ever gard.

    Thanks O2SILVER :thumb
    #8
  9. Nightstalker

    Nightstalker YO BUDDYPAL!

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    I just put it on and haven't ridden in the rain yet. It works real good in mud puddles though.

    You can get those cool Dakar stickers at:
    advrider.decaldude.com
    #9
  10. HappyGoLucky

    HappyGoLucky Goeie Grys Giftige Gert!

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    Why would he lie mate? Doesnt seem reasonable to come and do that. And I have heard of it happening before, which resulted in an instaneous addition of high fender. The fella came off hard and fast and over the bars, which could have hurt him pretty bad. But he wore Attgatt.
    #10
  11. marcel

    marcel Banned

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    I'am a little stinker
    HI NIGHTSTALKER , WOULD it be to much to ask for part no..... I`AM on LAZY side. YOUR bike look GREAT . BLACK VELVET.
    #11
  12. BLUE(UK)

    BLUE(UK) Long timer

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    Many people lie on forums to make themselves feel better but hey.....what the hell!!:huh
    #12
  13. Miguel

    Miguel off road junkie

    Joined:
    Jul 25, 2004
    Oddometer:
    590
    Location:
    Vancouver Island, BC
    Is anyone using the Touratech high fender kit? It seems pricey but I can't find any other sources? Does the back of the high fender hit the tank lobes and reduce turning diameter?
    #13
  14. 1stiski

    1stiski Ride that nasty thing

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    Elizabethville, PA
    Yo TZ, Bike looks good!!! I see you've got your street meats on for the ride up north... Have a safe one. Love-em-in-black. You've got taste, just like me.
    #14
  15. rvdcolf

    rvdcolf rvdcolf

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    Windhoek, Namibia
    Yeah, good question.... why would I lie?? Can show you the photo. And yes -the fender broke off, plus the brake line on left side.
    #15
  16. dgrs2

    dgrs2 Where'd I leave my knee??

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    Nice TZ :D Can't wait to get a look at it close up. Love the Dakar sticks going to place an order myself soon. Hope we can get together for a ride in the near future. Not in the heat!!! :norton
    #16
  17. Nightstalker

    Nightstalker YO BUDDYPAL!

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    Marcel, this is from a previous post:

    #17
  18. schew

    schew Wild Human

    Joined:
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    10
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    Colorado Adventurer
    I did the high fender conversion and single disk. I used the supermoto fender and of pfb's list you don't need the fender brace, screw fender brace, nut fender brace, bushings or 4 HH collar screws M6x20.

    I reused the same screws that held the brake cable guide to the lower triple clamp. the 2 HH collar screws I think I used to hold the side holes on the 85sx fork protectors.

    The fork protectors are close but don't really fit without some slotting of the holes and stretching with a heat gun, but they will work. The most difficult part of the job was getting the little black plastic plugs out of the side of the fork ends for the side holes of the fork protectors.
    #18
  19. Nightstalker

    Nightstalker YO BUDDYPAL!

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    Got some more parts in and installed tonight. Upper and lower brake hose guides.

    I ordered two of the KTM lower brake hose guides, part #600.08.019.000.

    I took the first guide, mounted it upside down on top of the original and cut the two in half down the middle. Bud Matto hooked me up with that bit of wisdom. Here's the finish product, side by side.
    [​IMG]

    Just reinstall above the fender and your set.

    Now, for the guide at the top of the forks. I had expected to fabricate something and just use the plastic guide loop from the KTM part. After eyeing up the situation, I cut the stock part and installed as shown.
    [​IMG]
    [​IMG]

    The wire ties were installed while I was waiting for parts and inspiration. I still need to remove the outer guide loop, it gently grazes the dash below the tach with the handle bars turned fully to the left. Also, the length from the mounting point to the center of the guide loop could be just a little bit long to be spot on. We'll see how it hold up this weekend.
    #19
  20. Katoum

    Katoum Adventurer

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    British Columbia, Canada
    Why would he lie, if you have not experienced it first hand don't be so quick to judge. I watched by friend crash 4 times and have the video to prove it. It came about by the front wheel becoming clogged with clay. The front wheel stops turning as soon as the friction from wheel to fender becomes greater that wheel to ground. Yes the fender gets stretched far forward, but the brake line attachment kept it from getting ripped off. This has happened to several people on this forum. A rock in the mix probably just made it happen all the faster.
    #20