Replacing old-style front brake line

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Orangecicle, Feb 11, 2012.

  1. Orangecicle

    Orangecicle On a "Quest"

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    I have an original 2005 front brake setup with the brake line that crosses over the low fender. I want to switch that to the modern setup with separate lines that joint together under the triples. Does anyone have the list of parts that works for this conversion? I know I want to avoid the ABS lines, but does one year of standard lines work better than another? I think the mounting bracket that goes under the triples should work fine, but I'm really not sure about the right lines to use.
    #1
  2. booger1

    booger1 Been here awhile

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    check out the HOW for the high fender.
    #2
  3. Orangecicle

    Orangecicle On a "Quest"

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    Nope. Not that setup. I'm looking for the setup that creates the brake line loops that stick out of the front of the bike.

    [​IMG]
    #3
  4. Goss

    Goss LC8 Adventurer

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    I have 2004 S model and have been contemplating the same mod so I can go from low to high fender when I want. I have the Touratech high fender kit but did not like the brake line routing and large loop at the master.

    I looked around in all the posts some time back and never found that parts list. I plan to go through the exploded parts view of a newer S model that uses this setup and simply write down the part numbers and order everything. Given the length of time KTM parts have been delivered I should have this accomplished in a year or so. Ha !
    #4
  5. Orangecicle

    Orangecicle On a "Quest"

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    Let's stay in touch. I'm thinking I'll order 2010 or 2011 parts and try to make it work. I can't wait to get rid of that big brake line loop that sticks right up in line with my gauges. Oh, I've also had pretty good luck with Powersports Warehouse.
    #5
  6. Geek

    Geek oot & aboot

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    How did you twist your brake line? I've never even noticed mine let alone had it block the instruments :dunno

    [​IMG]
    #6
  7. Orangecicle

    Orangecicle On a "Quest"

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    Mine doesn't have the loop, so it just sticks up. Came that way. :D
    #7
  8. Orangecicle

    Orangecicle On a "Quest"

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    I'm going to do this. My biggest issue in trying to figure out what length of front brake line to get -- the standard (non-ABS) or the "R" version. I think I need the "R" height. My June 2004 (i.e., 2005) KTM has always seemed much taller than the newer standards. Have a look at the axles in comparison to the bash plates.

    A 2010 "R".

    [​IMG]

    My bike:

    [​IMG]

    I think they look comparable, so I'm going with the "R" length line for my bike. Here are the part numbers that I'm ordering

    • 6011301200033 -- the front line (1)
    • 60101078000 -- the triple bracket (1)
    • 0603100141 -- banjo washers (6)
    • 50213025000 - new banjo bolts. (2)
    • 60101077000 - brake line guide for triples. (1)
    • 60101079000 - another guide (1)
    • 0012060164 - screws to mount the plastic guides (3)

    I may not need the banjo bolts, but they aren't expensive. Total costs at PSW looks to be may $110 before shipping. I still need to track down the screws that hold the plastic bracket on the bottom of the triples.
    #8
  9. Douf

    Douf Limey Bitch

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    I vaugely remember someone mentioned that the 990 tee pipe wasn't really wide enough to clear the high fender without some fit compromise. It seems like the only viable option would be a custom piece (like the one Pyndon made); an excellent opportunity for one of our more industrious inmates...

    Douf
    #9
  10. rinho

    rinho Rinho Féroce

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    I'm also thinking doing this... 2010R being the model with the bigger travel, I guess I'll go this way
    (the S between wheel and triple clamp may be a little bit bigger)
    #10
  11. Dusty

    Dusty Long timer

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    A couple plastic spacers will give enough clearance for the high fender.:freaky
    on the 990 anyways.
    #11
  12. rinho

    rinho Rinho Féroce

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    Nice!
    [​IMG]
    #12
  13. Geek

    Geek oot & aboot

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    Your bike is on the centerstand (suspension unloaded). :deal
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  14. Orangecicle

    Orangecicle On a "Quest"

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    So, I got all of the parts to switch out the front brake line. However, I can't tell from the schematic how I am supposed to mount these two little guides. Does anyone with a 990 have a picture or can you explain to me what I am supposed to do with these two guides?

    [​IMG]
    #14
  15. gefr

    gefr Life is a trip

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    IIRC correcly, there should be threaded holes ot the lower surface of the upper triple clamp.
    Cheers.
    #15
  16. Orangecicle

    Orangecicle On a "Quest"

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    Well, I tried to install the front line from the 2010 Orange chassis. That part number is 60142011000. That line must be for the ABS bikes because there is enough brake line to reach back to underneath the seat -- way too much to make the line usable for me. I've seen a thread where a guy used the front line from a 2007 S model. That part number is 60113012000. The line from the 2010 R model is 6011301200033.

    Any guesses of what changed in the line for the 2010 model?
    #16
  17. Goss

    Goss LC8 Adventurer

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    Just now checking back in on this.

    Since the 990 ABS module is under the seat it makes sense that the line you got is so long. Defintely have to have an "S" or "R" part number for that section.

    Sorry your the lab rat on this but once you get it all sorted out the rest of us will know what to get.:evil
    #17
  18. Orangecicle

    Orangecicle On a "Quest"

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    I finally had a day free to install the new front brake lines. I really like this change a lot. I hated how the old lines jutted up in front of the bars. Now the cockpit is nice and tidy:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #18
  19. AdvGa

    AdvGa Long timer

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    Boy it does look nice.... Great Job!
    #19
  20. rinho

    rinho Rinho Féroce

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    Wich part number did you finally use ?
    #20