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Old 10-01-2007, 04:24 PM   #16
Stephen
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Three kg is a lot, indeed.

Way to go, Rory. What would we do without you?

I really like this.

So, now the bracket comes with the brake -- Gregor had to make his own.
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Old 10-01-2007, 04:34 PM   #17
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Quote:
Originally Posted by Stephen
So, now the bracket comes with the brake -- Gregor had to make his own.
Thank you Stephen for your kind words

A big thanks to Mateo (Barbasma) on his advice
I ordered the brake kit for the 620/625/640 KTM
Molto bene!
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Old 10-01-2007, 07:20 PM   #18
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Quote:
Originally Posted by LC8Lewy
Ok so it was just people who hadn't done it before saying it wouldn't work
So.... who was it that said it couldn't be done??? Been there... done that.... years ago!
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Old 10-01-2007, 07:23 PM   #19
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Howza bouta...

could you mount up two of the 320's? or is the caliper only set up for one side (that is a brake line port on one end)

Wow, two 320s would be cool.
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Old 10-02-2007, 09:34 AM   #20
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Quote:
Originally Posted by KrustyKustom
could you mount up two of the 320's? or is the caliper only set up for one side (that is a brake line port on one end)

Wow, two 320s would be cool.
It will not mount on the other side How much is to much?
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Old 10-02-2007, 09:55 AM   #21
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Quote:
Originally Posted by MvZee
So.... who was it that said it couldn't be done??? Been there... done that.... years ago!
Don't stop there! http://www.advrider.com/forums/showt...ht=single+disk

The thing is that no one finished the job off, there was always something left to do....... or try. The reason your rotor failed, I think ,is because the brake was not mounted properly. This story had never been finished.

"Quote =Mvzee
What do you mean... never completed -- did you read the whole thread? Specifically this post where I commented about it's performance on an 8000 mile trip around Mexico?

Now for an update... I recently had to replace the Motomaster rotor as it got really sloppy. I replaced it with a 320mm Galfer rotor which will hopefully last a bit longer. I also think that this conversion truly needs a different master cylinder for the Motomaster caliper. I think a 16mm radial master cylinder might be the ticket. It takes considerably more pressure on the lever to stop than with the stock brakes.

Would I do it again? Probably not -- I think that the new 300 mm rotors now available from Galfer are probably a more cost effective and easier solution, although the weight savings would probably be less. With a 4 piston caliper and 320 mm rotor, clearance between the caliper and the spokes is close. In fact, it may not even be possible with some calipers... the Motomaster is one of the narrowest and my clearance is on the (very) tight side even with the rotor spaced out from the hub about 0.100". I think the solution for the clearance problem is re-lacing the wheel with some "dish" (like a rear bicycle wheel) and then recentering it with new axle bushings -- but that's a project for another day....
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Old 10-04-2007, 09:21 PM   #22
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Quote:
Originally Posted by K2m
Don't stop there! http://www.advrider.com/forums/showt...ht=single+disk

The thing is that no one finished the job off, there was always something left to do....... or try. The reason your rotor failed, I think ,is because the brake was not mounted properly. This story had never been finished.

"Quote =Mvzee
What do you mean... never completed -- did you read the whole thread? Specifically this post where I commented about it's performance on an 8000 mile trip around Mexico?

Now for an update... I recently had to replace the Motomaster rotor as it got really sloppy. I replaced it with a 320mm Galfer rotor which will hopefully last a bit longer. I also think that this conversion truly needs a different master cylinder for the Motomaster caliper. I think a 16mm radial master cylinder might be the ticket. It takes considerably more pressure on the lever to stop than with the stock brakes.

Would I do it again? Probably not -- I think that the new 300 mm rotors now available from Galfer are probably a more cost effective and easier solution, although the weight savings would probably be less. With a 4 piston caliper and 320 mm rotor, clearance between the caliper and the spokes is close. In fact, it may not even be possible with some calipers... the Motomaster is one of the narrowest and my clearance is on the (very) tight side even with the rotor spaced out from the hub about 0.100". I think the solution for the clearance problem is re-lacing the wheel with some "dish" (like a rear bicycle wheel) and then recentering it with new axle bushings -- but that's a project for another day....
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Sure... get back to me when you have over 8k miles on your Motomaster rotor!
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Old 12-03-2007, 05:26 PM   #23
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Quote:
Originally Posted by K2m
This brake is much stronger than the standard twin disks. There is excellent feedback through the SE master cylinder. I have had it on for a month, but have not been on the dirt yet.
I've done about 1200km on the dirt, fully loaded, now with this brake, and simply love it. Full control on the loos-es of surfaces. Simply brilliant
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Old 12-03-2007, 08:44 PM   #24
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Nice job Rory.

When I was in this dilemma on a different (but similar project), I got a KTM factory SM rotor spacer and milled it to fit to work with the 21" wheel and the standard caliper hanger offset.







This should work to adapt a SM brake to most any 4860 forked KTM to a 21" wheel. The big headache is the caliper to spoke clearance for those that haven't tried this.

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Old 01-31-2008, 02:14 PM   #25
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Gaspipe.... sorry it took so long to reply...... I was so impressed by your photos that i went out and bought a small mill. I didn't even know what a mill was!!!

Man!!! what a useful machine!!!!

I had to make some "leak jet" circuits for the FCR's fuel pumps. Didn't have a clue what the fuck I was doing

Fucked it up, of course could not get the threads to seal so I epoxied them in........ Any body want to buy some unused leak jets various sizes?

Lucky, as it turns out, I chose the right size.

Of course you learn by your mistakes, the trick is to drill and complete one hole in one operation including using the mill to tap the thread. Just turn it by hand

Forget useless bench drills..... A mill is the way to go

[IMG][/IMG]
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Old 04-21-2008, 05:03 PM   #26
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is it all worth it

the brake kit and having to change brake master cyclinder sound expensive..

I get the benifits, but how much is the conversion?

I am in Australia also.

Joe
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Old 06-17-2008, 10:50 PM   #27
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bump

Quote:
Originally Posted by mortaygo
the brake kit and having to change brake master cyclinder sound expensive..

I get the benifits, but how much is the conversion?

I am in Australia also.

Joe
bump!!!! any answers?????????
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Old 06-18-2008, 05:23 AM   #28
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Worth every cent........ Master from an SE $180AU

Disk and caliper from Motostrano $550USD on special.

http://www.motostrano.com/enbrakclut1.html

$I50USD freight 4 days UPS.

I will never change back to twin disk so I will cut of the redundant caliper carrier. Just wish I had have known so as to get a SE front hub with out disk carrier for my spare wheels. I will do this with my motard front wheel.

It's worth considering what your long term relationship with the bike is, and keep an eye open for special discounted prices.

The more weight you can get of this bike the more it behaves like a dirt bike. When traveling, correct weight distribution and a minimalist (Bush walker-cross country skier) approach to loading will allow you to tackle anything.

[IMG][/IMG][IMG][/IMG]
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Old 06-18-2008, 05:49 PM   #29
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thanks

Quote:
Originally Posted by K2m
Worth every cent........ Master from an SE $180AU

Disk and caliper from Motostrano $550USD on special.

http://www.motostrano.com/enbrakclut1.html

$I50USD freight 4 days UPS.

I will never change back to twin disk so I will cut of the redundant caliper carrier. Just wish I had have known so as to get a SE front hub with out disk carrier for my spare wheels. I will do this with my motard front wheel.

It's worth considering what your long term relationship with the bike is, and keep an eye open for special discounted prices.

The more weight you can get of this bike the more it behaves like a dirt bike. When traveling, correct weight distribution and a minimalist (Bush walker-cross country skier) approach to loading will allow you to tackle anything.

[IMG][/IMG][IMG][/IMG]
Thanks for taking the time to respond... I wonder if there are any cheaper kits in Oz now - galfer or someone like that. Just a shame to pay the $150 in freight...

Great work, thanks for leading the way!

Joe
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Old 09-04-2008, 03:44 PM   #30
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well I bit the bullet

Thanks for the support from some others here - but a special thanks to Rory who lead the way and gave me advice on my conversion. Haven't ridden the bike yet but who cares it looks hot!!!! ha ha ha.. nah - can't wait to ride it!!

I first went to a single disc, with the SE master cylinder - was good on the dirt and I certainly noticed a difference in the unsprung weight (I must admit when people first spoke of the difference 3kgs off the front would make a big difference I thought - nah couldn't) It really is noticable. There just wasn't enough braking power on the tar or in emergency braking situations.

I followed Rory's lead and later Flanny's and fitted the motomaster 320mm disc and 4 pot caliper.


I fitted it up last night using Rory's tips and it all went together well. I just need to get some nice little button head bolts 5mm longer for the disc. I put a few dodgy bolts in last night just to fit it up. Using the little button head bolts the speedo sensor can be mounted in the original position, I just hope that it picks up the bolts..... will know tonight.

[IMG][/IMG]

looks hot hey!!!

[IMG][/IMG]


bleed up nicley last night and disc is running nice and free, with a tight fit but hopefully enough clearance.... I will installt he disc again tonight with the new bolts and go for a test ride over the weekend. I will post another picture and my thoughts after the ride... however this set up has already been tried and tested...


Nice!!!!!!!!!
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