HDB Rallye Lite Kit and Dual Sport fairing,

ROKIT_71 · Feb 9, 2013

Hello Paul,

Really like your set up and have some queries regarding it.

I'm picking up this week a 2103 Berg 501 to set up for the Condo 750 & The Australian Safari.

This kit would fit straight on I assume as it is a blue KTM!

With regard to the lighting do you need to upgrade anything. Will standard wiring set up handle the Squadron LED lights? Can they run high and low beam? Do they plug straight in?

How much are the handlebars raised to accommodate the set up?

Can you ship to Australia?

Thanks mate and great work!

Knobbiethrower · Feb 9, 2013

Will the KTM KIT fit a 2011 Husaber 570 FE?

theantipaul · Feb 9, 2013

KTBen said: ↑

This is a great idea (just what ive been thinking about)

Have you got a photo of a bike with the black fairing? Maybe even a photo of one on a bigger bike.....
Click to expand...

Ben, we've sold out of the first batches, they were only white, have machine time booked for production on the tool end of next week will have white, black and orange then. As far as a bigger bike, haven't tried yet, really focusing on getting the kits for Honda's and Yamaha's done first. What bike are we talking about?

ROKIT_71 said: ↑

 Hello Paul,

Really like your set up and have some queries regarding it.

I'm picking up this week a 2103 Berg 501 to set up for the Condo 750 & The Australian Safari.

This kit would fit straight on I assume as it is a blue KTM!

With regard to the lighting do you need to upgrade anything. Will standard wiring set up handle the Squadron LED lights? Can they run high and low beam? Do they plug straight in?

How much are the handlebars raised to accommodate the set up?

Can you ship to Australia?

Thanks mate and great work!


Click to expand...

Rokit, the only thing I'm concerned about is the lower triple mount on that and the new KTM XC-F and SX, they have front mounts on the lower triple for the fenders and no tapped holes on the top of the lower triple, I'll need to try the lower mounting bracket on one to see.

Looks like the 501 will have enough power, same as my 500XCW, but you'll need to do some wiring for the lights and switches, and you'll want to fuse them separately so that if one shorts or has an issue they both don't go dark.

The Squadrons come in spot, flood, combo and wide cornering. None are DOT or street legal, but as mentioned they can be made to pass if the scrutiny isn't too bad. They do come in a plug and play config for KTM's, but if you have 2 you'll still want separate switching and fusing.

The lowest configuration for the bars would be less than an inch over stock to allow for the damper submt.

Yes I can ship to Australia, but USPS has just increased their international shipping rates 25%+ so that might hurt.

I can get you a quote, email me what you would like to order.

Knobbiethrower said: ↑

Will the KTM KIT fit a 2011 Husaber 570 FE?
Click to expand...

KBT, Microfiche on the 570 looks like if it's stock should work, but really just needs the triples with those holes on the triple pictured above. You can email me some pics of yours and I should be able to tell.

theantipaul · Feb 9, 2013

As Idahombre mentioned before, the ADV 10% discount code has never been turned off and don't have any plans to do so. That should help take the edge off the shipping.

KTBen · Feb 9, 2013

It would be for a 690 enduro. Looking at your photos it looks like it would fit straight on. Can you post a photo of a black fairing when you've made them.

rmhrc628 · Feb 9, 2013

theantipaul said: ↑

We start here, this is the style KTM triple clamp for this setup, versions to follow would be for Hondas, Yamahas and aftermarket triples, BRP etc.

On go the Scotts submt/side plate mt and the lower handlebar clamps, these are 2 12 with the submt the overall height to the centerline of the bars is 3 1/8,

Adjustable Scotts mounting plate,

Top clamp,

Next comes the lower bracket,

Then the first side plate,

Then the lower side plate and spacer to tie it all together, the side plate is tapped for the M6 bolt and the only drilling required if needed is to drill through the lower side plate at the hole above the bolt and add a second bolt, we have found this to be pretty much unnecessary, but have kept it for unknown abuse.

Here are 2 optional Squadrons and hardware ready for mounting,

The squadrons mounted up,

And with the fairing.

The whole package weighs in at 7.5lbs, but that includes submt, lowers and top clamp, your bike will already have these,

So the assembly as it sits that can be removed to return to stock light, weighs in at 4.5lbs,

Click to expand...

Paul

May I ask the exact model of renthal evo handlebars you run?

What do you think of them for adv riding?

I'm considering swapping out my pro taper cr highs for some 'straighter' bars.

DirtJack · Feb 10, 2013

Paul,

I have the HDB hand guard setup on my 990 and 690E and really like them but I do have a problem with the 690 which is illustrated in the picture below:

The bar top-clamp blocks the view of the instruments and, when I mount my Zumo on a bar which uses the two tapped holes in the top-clamp, the partial view of the instruments is completely gone. I've been thinking of trying to use the Rally Lite setup to solve this problem and also improve the lighting significantly. So the question is (and other 690 owners may have this question too), Do you have a mount for the 08 690E instrument? I realize there are not that many 08 E's out there. but the 2012 and 2013 690 R's also use this instrument cluster. I guess I could try to fab something myself which would attach to the lite setup, but the esthetics of that would likely be something I wouldn't want to look at each time I ride.

Finally, I assume that I would be able to buy just the parts of the Rally Lite setup I need, correct? I understand that I would be replacing my current Scott's mount and bar mount, but hopefully not the bar top-clamp.

Motorfiets · Feb 10, 2013

Do you have rox offset riders? Are you bolting the top top clamp directly onto the OEM lowers?

DirtJack · Feb 10, 2013

Motorfiets said: ↑

Do you have rox offset riders? Are you bolting the top top clamp directly onto the OEM lowers?
Click to expand...

The 690 Scott mount was from Underground Machine (2" risers). The stock bar lower-mounts bolt to the Scott's mount.

Motorfiets · Feb 10, 2013

DirtJack said: ↑

The 690 Scott mount was from Underground Machine (2" risers). The stock bar lower-mounts bolt to the Scott's mount.
Click to expand...

From the thread you showed me... it looks like even with the OEM top clamp, guys are already crowding their instruments

Paul will most likely answer you... but from what I can see the best bet would be the get a different top clamp AKA big holes on bottom

OR Go with this setup -

DirtJack · Feb 10, 2013

Motorfiets said: ↑

OR Go with this setup -

Click to expand...

That mount looks exactly like what I am looking for. Thanks.

Motorfiets · Feb 10, 2013

DirtJack said: ↑

That mount looks exactly like what I am looking for. Thanks.
Click to expand...

I think it was a custom job... BUT... Paul is really good about making custom orders

theantipaul · Feb 10, 2013

rmhrc628 said: ↑

Paul

May I ask the exact model of renthal evo handlebars you run?

What do you think of them for adv riding?

I'm considering swapping out my pro taper cr highs for some 'straighter' bars.
Click to expand...

I'm running YZ High's right now, they are about as flat as the stock KTM's and at just over 3" not exactly high, but I like them so far. Evo's are proving to be very strong. Bars are a real personal thing though.

DirtJack said: ↑

That mount looks exactly like what I am looking for. Thanks.
Click to expand...

We can look at making something similar, that was a big chunk of aluminum with most of it removed, it would be kind of pricey the way it sits and routing the brake line down to the lower triple would be advisable even without the tower.

I still have the files, there just wasn't much demand.

Motorfiets said: ↑

I think it was a custom job... BUT... Paul is really good about making custom orders
Click to expand...

Ben, you're going to get me in trouble!

crankshaft · Feb 10, 2013

I can't believe I missed this thread! Been running the rally light on my 2011 390 Berg and my 690 KTM all summer/winter and it's held up to lots of New England trail abuse.

Unadilla GNCC race was fun with the rally lite, I even tangled with a few riders and it never missed a beat....

For Xmas decoration...

On the ice on my 690...

<iframe width="560" height="315" src="http://www.youtube.com/embed/7OAL4lm3Eac" frameborder="0" allowfullscreen></iframe>

Rode this J-day race with the tower on and actually cross rutted and hit a tree pretty hard Zero damage, I was amazed! You can see how nasty the terrain is and the extreme section was rugged.

<iframe width="560" height="315" src="http://www.youtube.com/embed/2jN7WfSIw0Q" frameborder="0" allowfullscreen></iframe>

Here is a gallery of photo's of the rally light mount on my 690 and on my Berg, should give even more details.

https://crankshaft.smugmug.com/Other/690-Rally/23750124_nNxsGK#!i=1923503086&k=VsJsp9S

Here is what I've been working on this weekend....

Paul instructed me to try and snap one off the front of my bike and I tried like hell but sadly couldn't manage it

Motorfiets · Feb 11, 2013

theantipaul said: ↑

Ben, you're going to get me in trouble!
Click to expand...

525 gets here sunday... I'll be hollering at you soon for some hopefully STANDARD run jobs...

p.s. - do you use gibbsCAM at all?

LukasM · Feb 12, 2013

Very nice pictures showing the install, can't wait to get mine on the bike!

Paul,

What combination of Squadron lense shapes would you recommend if going with two of them? One spot + one flood?

theantipaul · Feb 12, 2013

Motorfiets said: ↑

525 gets here sunday... I'll be hollering at you soon for some hopefully STANDARD run jobs...

p.s. - do you use gibbsCAM at all?
Click to expand...

Let me see it when you get it, I use CamWorks a plugin for SolidWorks.

LukasM said: ↑

Very nice pictures showing the install, can't wait to get mine on the bike!

Paul,

What combination of Squadron lense shapes would you recommend if going with two of them? One spot + one flood?
Click to expand...

I use a spot down low and a wide cornering on top, the WC lens produces a nice band of usable light, I think better then the flood while maintaining a decent halo.

You can see it pretty good in the video, thing is that trail is pretty steep so it looks like they are directed too far down, on level ground they don't look so poorly aimed.

<iframe src="http://www.youtube.com/embed/MaAmz5dnl90?feature=player_embedded" allowfullscreen="" frameborder="0" height="360" width="640"></iframe>

tlwood99 · Feb 19, 2013

theantipaul · Feb 20, 2013

tlwood99 said: ↑

Click to expand...

We sold out of our first 15 sets and we're waiting on production parts from the molders and the water jet shop.

We have the prototypes for the WR's and CRF's done and waiting to get them scheduled for fitting.

Also refining things a bit, thanks to Richard, not sure if he's an inmate here, we're incorporating his suggestion for replacing the spacers at the lower mount with a plate that mounts the P-clamps.

Next batch of towers should ship in about 2 weeks.

Yellow Pig · Feb 21, 2013

Nice!

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