To go with the high mudguard I’ve designed some brake hose guides to fit on the fork legs with a cable tie.
3D printer files here.
KTM – Hose Guide
KTM – High Front Mudguard and Fork Guards
Bit of a work in progress, but getting there.
Front mudguard is sorted and am designing some adapters to allow fork guards to fit the 990 forks as the bottom bolt holes are too close together to accept anything ‘off the shelf’.
Currently I’ve designed an adapter that I’ve 3D printed allowing KTM 85SX 2004 – 2017 fork guards to be fitted.
There’s a hidden bolt under the guard which secures the adapter to the fork leg, once I’ve got the design sorted for both sides, as the guards are slightly different on each side, I’ll publish the STL files.
Bolts are M6x16mm countersunk and 2 – M6x20mm flange button head
3D printer files for adapters here.
Currently removed the Z Adventure diffuser from under the fairing, but will see if that can be refitted once I’ve worked everything out.
KTM – Rear Wheel Overhaul
I’d started changing a few rusty spokes, which you can do with the wheel in the bike, just let the tyre pressure down fairly low just enough to stop the nipple falling inside the rim, then unscrew the nipple and remove the spoke.
However on closer inspection most of the nipples were rusty, so I decided remove the tyre and strip the wheel, doing wheel bearings and seals at the same time.
Spokes and nipples came from SM Pro Wheels. Who are part of Central Wheel Components.
Job was pretty straight forward pull bearings, ones in the hub I pressed out then swap spokes and nipples. Due to the spoke lacing I found it easier to do groups of 3 spokes then rotate the wheel 180 and do another 3 to keep the rim true.
Bearing and seal part numbers are shown in the gallery. One side of the wheel has a Nilos seal which is basically a metal washer. Bearing used were all Koyo. I also replaced all the cush drive rubbers with parts from Gear 4 Motorcycles.
The closeup pictures of the rim show changing individual spokes. Once undone with my spoke tool, I unscrewed the head to allow me to spin it between the spokes for removal. All of the spokes were corroded in and required pliers to assist in their removal.
Hub was given a full clean prior to reassembly.
Anthony at Haines fitted and balanced a new Pirelli Scorpion rear tyre for me and when balancing confirmed the rim was perfectly true. Interestingly he was also able to remove most of those enormous lead weights you can see in the photos, as they weren’t required to balance the tyre.
KTM – Footpeg Extensions
More 4k Parti Speciali bits – footpeg extensions, functional and look great.
Once I removed the stock ones I discovered the mounting pins were very worn, so swapped them for some stainless ones I had left over from the CCM project plus stainless split pins and washers. I was also able to add a slim stainless washer to take out some of the play in the mount.
You have to drill 3 small holes in each footpeg, just pay attention to where the webs are on each peg. I used hose clamp pliers to fit the springs, as they’re a bastard to fit otherwise.
KTM – Side Stand
Finally well enough to catch up on some of the jobs I’d bought parts for. First is to fit a side stand relocation kit and the side stand I bought from 4k Parti Speciali.
Side Stand relocation Kit
Main reason for this is the stock side stand is bolted to the engine case and if you do hit something of road there’s a chance of smashing the engine case. So I bought a kit from Charlie Nut and bolted it on, only thing I’m going to do is swap out the bolts for stainless ones as there at the bottom of the engine where all the muck from the road will corrode standard bolts.
Kit was easy to fit, just follow their instructions, obviously cleaning as you go 🙂 I’ll redo the photos when I swap the bolts as was feeling crap on the day I did the work.
4K Parti Speciali Side Stand
This stand kit is great on many counts, first it is adjustable for long or short travel suspension, secondly its designed to tuck in closer to the frame and finally it looks great.
Once is unbolted the standard side stand it was apparent that the mounting bracket and bolt were both worn introducing lots of play and the springs had been bent and some stage so I had a quick trip to the local KTM dealers to pick up new parts.
The only mod I made to the 4k stand was to add longer bolts to the foot and dome nuts to ensure its safe from vibrations plus medium loctite.
I’m also going to investigate removing the side stand switch as it looks like a weak point if it gets broken off road, is ridiculously expensive to replace and unnecessary as bikes didn’t use to have them, just more shit to go wrong at the wrong time.
KTM – Rear Light
There are two things I’ve always disliked about the Adventure and that’s the indicators and enormous rear light. Indicators were fixed with KTM EXC ones and the rear light has now been sorted with a kit from Twalcom in Italy. They do a great range of upgrade parts, unfortunately in the UK we get hit with import fees due to the Brexit fuckwits.
The kit consists of a modified led rear light, some aluminium brackets and a custom number plate holder that is quick release if you’re off roading.
Fitting is easy, basically remove rear light and mount, swap some spacers over and fit new bracket etc. Only issue for the UK is the number plate holder isn’t the right shape for our number plates, so as a temp fix I just added a flexible plate at the top of the holder. When I get some free time I’ll design and 3D print one for UK plates.
The improvement is massive and highly recommended!
KTM – QR Glovebox
Bought one of Z Adventure‘s QR glovebox brackets. Good value and dead easy to fit.
My only issue was the bottom moulding had previously been drilled for a 12v socket, so tried to buy a new one to find, after weeks of waiting, its no longer in production.
Months of eBay searches revealed a NOS one the other day which I now have.
Certainly will make air filter changes a lot easier in the future, whilst I was at it I added a K&N filter.
I noticed when fitting the K&N that the secondary butterflies have been removed so guess some tuning has happened in the past, will checkout the engine mapping when I get a chance.
KTM – Lighting Upgrade
The bike came with a HID conversion but I didn’t like the buzzing noise from the HID controller and want to lose any weight I can, so I removed the HID wiring and bought some LED bulbs.
Only issue at the moment is I’m still looking for rubber cover that will fit the high beam bulb as the one I bought has a large heatsink.
You can see the difference the lighting has gone from the blue tone to a much whiter one. IF the bulbs would have been standard the difference would be massive.
Highly recommended and cheap improvement. Bulbs are H7 dipped and H3 high beam, I bought 20Twenty bulbs, only issue was the dipped ones came as a pair but I guess a spare is always useful.
KTM – Brake Pedal Refurb
Catching up on items done just before I moved into chaos.
Brake pedal had my standard steps –
- Dismantle
- Clean
- Blast
- Repaint
Fitted new Stainless allen bolts to the pedal, a new bearing – 6082rs and made a new stainless adjuster out of an M6 bolt, cut to length then filed the end round.
Nearly Back
Its been a bloody nightmare with ridiculous builder’s quotes. So garage rebuild has been shelved, as I’d rather spend £50k on bikes.
Managed to get the KTM home and have been doing a few maintenance jobs, but the garage has a long way to go. Fitting the door nearly killed me, as I had to do it by myself, so removing the old patio doors, what were they thinking, and then fitting the up and over door was hard work.
Next need to get shelving sorted so that I can get my tools and gear back and get rid of the bloody cardboard boxes.
