Hybrid front fender (half road/half dirt)

[mcmann]

Good idea . . . I made my 1/4" X 1" aluminum rear support over an inch 1 3/4" higher. I should get my SE fender and 2nd brake line soon. This hybrid fender w/OEM fork guards is not designed for sticky mud . . . Only occasional vey light mud. If I do run into the sticky stuff . . . I will remove the fork guards etc.





The 800GS fender broke on a dry dirt road . . . Which is it what I was referring too. You definitely do not want a low fender in the mud. The Adv OEM fender sould be OK in dry conditions.

800GS fender snapping:


Yikes . . . Raising a low fender wouldn't help in this mud!

[Orangecicle]

Originally Posted by RedRupert

Thanks for the link.

Your bikes looks like a 2004: seat (by 2005 they had a stepped seat) and the heat shield (looks as if yours stops at the frame - 2005s extended back further). If you're interested to know if your suspension is 210 or 230 travel, you can measure it with no load on the front forks - just measure from top of axle clamp to bottom of dust seal.

Well, I measured my travel with no load on the front forks, and it measures out at about 9.25 inches, which converts to 235mm??? So, I'm guessing that my bike has forks from the original '03-'04 bikes? It's at least 230mm, for sure. I always knew the dang thing was tall!!!

My bike is weird. The bike was obtained originally by a KTM rep. who was responsible for promoting the brand to dealers. I say "obtained" because he got the bike from KTM but didn't actually title it in his name for a couple of years, which greatly lowered the bike's cost to him. He traveled on the bike and displayed it at bike shows. He had access to anything he wanted from KTM, so if he wanted taller travel they just bolted it up for him. The bike came with everything KTM was selling at the time, including a Corbin seat that KTM was promoting.

I thought the stepped seat came along with the 2005.5 bikes. Dunno.

[Orangecicle]

Originally Posted by mcmann

Good idea . . . I made my 1/4" X 1" aluminum rear support over an inch higher. I will remove the rear plastic fender material from behind my support when I eliminate the cross-over brake line. . . .

Just a suggestion, but I wouldn't put that brace on. The idea of removing the crossover brake line is to remove something that might one day fall down and grab the front tire. It's OK to destroy a front fender -- no big worries there. But, if what happened to LostRider happened on pavement resulting in a stoppie at speed. . . . That would be bad. So my goal was to remove anything that might grab the tire. I think your brace could grab the tire. So, I just offer the suggestion that you might not want to put that on. Raise the low fender and call it good. That's my plan.

[mcmann]

You make a very good point.

I made sure my rear support could not make contact with the tire. When it is bolted tight (w/lock-tight), it makes contact with the caliper bracket which keeps it in place. I loosened the bolts to check clearance . . . The bracket hits the lower shock housing and will not allow it to rub the tire.



Loose position:



I have good clearance when all the way forward if the bolts came loose and fender snapped from mud etc.



The plastic fender supports also help hold everything in place:

[FakeName]

Originally Posted by mcmann

You make a very good point.

I made sure my rear support could not make contact with the tire.

You've clearly given this a bit of thought, and to each their own.

But I wouldn't run it. Gives me the heebie-jeebies just looking at it.

[MortimerSickle]

Originally Posted by Orangecicle

Well, I measured my travel with no load on the front forks, and it measures out at about 9.25 inches, which converts to 235mm??? So, I'm guessing that my bike has forks from the original '03-'04 bikes? It's at least 230mm, for sure. I always knew the dang thing was tall!!!
...

Originally Posted by Pyndon

...

2003 Adventure = 230mm travel
2003 Adventure 'S' = 265mm travel
2004 Adventure = 230mm travel
2004 Adventure 'S' = 265mm travel
2005 Adventure = 210mm travel
2005 Adventure 'S' = 245mm travel
2006 Adventure = 210mm travel
2006 Adventure 'S' = 245mm travel

...

.

[mcmann]

Originally Posted by FakeName

You've clearly given this a bit of thought, and to each their own.

But I wouldn't run it. Gives me the heebie-jeebies just looking at it.

After second thought . . . .I don't really need this support for fork guards . . . So I wacked it off . . . Then I went outside and cut my fender off with only enough material to help support the fork protectors.

Thanks again . . . Better to be safe . . . Which was my main intention when I ordered the 2nd brake line.

[FakeName]

Originally Posted by mcmann

. . . So I wacked it off . .

oh. Well...

[mcmann]

Finished.

My order came in @ 6:30 PM Saturday.

The SE fender fit perfectly. I added the 2nd right brake line similar to the left . . . Using a steel hose clamp to secure it to the OEM fork guards. The center portion of the fork guard is simiar to a dirt bike fork brace . . . Should not limit mud riding much. It keeps the top of the fork guards secure . . . Which holds the brake lines in place:

[RedRupert]

Originally Posted by Orangecicle

Well, I measured my travel with no load on the front forks, and it measures out at about 9.25 inches, which converts to 235mm??? So, I'm guessing that my bike has forks from the original '03-'04 bikes? It's at least 230mm, for sure. I always knew the dang thing was tall!!!

My bike is weird. The bike was obtained originally by a KTM rep. who was responsible for promoting the brand to dealers. I say "obtained" because he got the bike from KTM but didn't actually title it in his name for a couple of years, which greatly lowered the bike's cost to him. He traveled on the bike and displayed it at bike shows. He had access to anything he wanted from KTM, so if he wanted taller travel they just bolted it up for him. The bike came with everything KTM was selling at the time, including a Corbin seat that KTM was promoting.

I thought the stepped seat came along with the 2005.5 bikes. Dunno.

Yes, I'm sure it's a 2004.

You can be 100% when you check the engine number and VIN:

Engine
04 600 xxxxx is a 2004 Adventure
05 600 xxxxx is a 2005 Adventure

VIN
Look for the number after the 'X'
X4 = 2004
X5 = 2005

You could also ask your dealer to print-out the KTM DealerNet record for your bike - it'll show production and shipment dates etc.

The stepped seat came in 2005 along with the change in height/suspension travel - you Yanks got the bikes a little late, so invented 2005.5

[Orangecicle]

Originally Posted by RedRupert

Yes, I'm sure it's a 2004.

You can be 100% when you check the engine number and VIN:

Engine
04 600 xxxxx is a 2004 Adventure
05 600 xxxxx is a 2005 Adventure

VIN
Look for the number after the 'X'
X4 = 2004
X5 = 2005

You could also ask your dealer to print-out the KTM DealerNet record for your bike - it'll show production and shipment dates etc.

The stepped seat came in 2005 along with the change in height/suspension travel - you Yanks got the bikes a little late, so invented 2005.5

Hey, what do you know? You're right!

[Qwik]

You really don't need the top portion of the stock fender.

[mcmann]

It helps support my brake lines. I do not ride much off road:
It is no different than a fork brace . . . Should not cause mud issues etc.

[DesertSurfer]

Originally Posted by mcmann

It helps support my brake lines. I do not ride much off road:
It is no different than a fork brace . . . Should not cause mud issues etc.

I first saw this version of fender application done by another inmate XTREMJEEPN ( Cole Ford of Motul Magazine) using cutdown version of low fender as a brake line mount combined with a high fender. It's very similar to the late model OEM KTM 690 Super Moto fender set up.

For some fun facts... The early 950 race bikes had an oil cooler up front which warranted the lower fender for space, better airflow to the cooler and radiator... and the loop around low fender oil line was an OEM bolt on to what was originally raced as a single rotor front brake set up.

Glad you're having fun with it.