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Old 01-22-2014, 07:08 PM   #9061
Foot dragger
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Joined: Dec 2006
Location: chico,just below rag dump(nor-cal)
Oddometer: 12,782
Today,I did some fettling of the 06 525EXC I just picked up,decided to go vintage on dualsport riding. Found a 46 hour clean 525.

Before that I picked up some slick Bulletproof designs radiator guards,perfect orange coloring,they go on the 2014 300XCW.

New singletrack bikes are especially good!
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Old 01-22-2014, 08:15 PM   #9062
BykBoy
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Location: Reston, VA
Oddometer: 528
ABS Relocation to to CPR Doghouse on a 990 Adv

I have a 2011 990 Adventure Dakar edition. I want to install Rade's underseat gas tank to extend the bike's range. Unfortunately, The ABS unit is getting in the way...

The idea is to remove the ABS unit from the stock location under the seat:



And re-locate it into the the CPR Doghouse.



There is not much room in the Doghouse, but the ABS unit just fits, and there is plenty of room for all the wires and break lines.

Removing ABS requires disconnecting the break lines and opening the three bottom screws that connect the holding bracket to the bottom of the rear fender. I had to remove the bottom bracket and cut the left edge off so that the ABS unit fit in the Doghouse.

First, I was going to cut it with the saw:



But then I got lazy and just used sheer cutter:



This is what the front side of the ABS unit and the bottom bracket look like after the cut:



Notice the pin that sticks out from the bottom of the unit and connects to the bottom plate. I had to drill a hole in bottom of the Doghouse so that the unit sits flat. I also drilled two hols in the bottom of the doghouse for screws to attach the bottom bracket in place:



Since the top of the Doghouse is almost flush with the underside of the seat, I had to cut four slots in the walls of the Doghouse to allow the ABS wiring harness and the brake lines through:



The front break lines are long enough to reach the relocated ABS. I re-routed the ABS wiring harness so that it runs in from the left side of the rear cylinder. I used the stock rubber sleeve to protect the harness and the brake lines from the sides of the slots.



Unfortunately, the rear brake lines are about 5 inches too short to reach the re-located ABS unit. I had custom lines made at a local auto supply shop.

The new short line is about 19" and the new long line is about 39".

These are the custom (top) and stock (bottom) lines that go from the ABS unit to the rear break reservoir:



These are the custom (top) and stock (bottom) lines that goes from the ABS unit to the rear brake caliper:



After connecting the rear brake lines, I'm ready to bolt everything down:



Since the ABS unit fits so tightly in the Doghouse, there is no space to put the small orange bracket that secures the Doghouse in place. Instead, I drilled a hole in the side wall of the doghouse and put one of the stock screws in frame bracket that holds the gas tank. You can see the screw under the sticker and above the black brake lines:



This is what it looks like from the left side.



And here it is, all tucked in and ready to go:



The ABS wiring harness is on the top left corner of the Doghouse. The rear brake lines are on the bottom left, front brake lines are on the bottom right, the wire that connects the ABS harness to the main harness is on the right side. The TuneECU plug and resistors are tucked into the black plastic tube on top of the ABS unit.

The hardest part of all this was to bolt everything down. There is very little space to work with once the ABS unit is in place. Getting the screws for the brackets that hold the Doghouse in place were the most challenging. It would be nice if the good folk at CPR could make a Doghouse that is already setup for the ABS relocation...
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Old 01-22-2014, 10:54 PM   #9063
rossguzzi
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Location: Bottom left hand side of OZ
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Nice work !

I`m still thinking I will ditch my abs. But I like your work.

I was thinking of the underseat tank, but I just won a set of Safari Tanks off evilbay foe 1k. So If I got the underseat tank (wich I still may do) I could use it to store water. Then get CJ`s side storage box and I have space for tools ect. Plus the dog house, Im sweet !
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Old 01-23-2014, 01:12 AM   #9064
KTMbageera
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Location: Kingdom of Cambodia
Oddometer: 88
Orange everywhere in Cambodia

There are lots of KTM fans in Cambodia. Everywhere you look, there are guys in our favourite colour. They are so excited to see KTM's rolling throughout the Kingdom.

I am sporting new graphics I designed and had cut here. Completely reflective 3M glow in the headlights materials. Cost me $30 for the sticker wizards to cut and apply.




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Old 01-23-2014, 01:59 AM   #9065
macleod
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That was a fine job. I was thinking at Rade's tank but ABS was the way. Now there's a new chance.
Thanks for the walk through.

Quote:
Originally Posted by BykBoy View Post
I have a 2011 990 Adventure Dakar edition. I want to install Rade's underseat gas tank to extend the bike's range. Unfortunately, The ABS unit is getting in the way...

The idea is to remove the ABS unit from the stock location under the seat:



And re-locate it into the the CPR Doghouse.



There is not much room in the Doghouse, but the ABS unit just fits, and there is plenty of room for all the wires and


Sent from my Nexus 4 using Tapatalk
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Old 01-23-2014, 06:52 AM   #9066
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Took her for an ice ride in Peru

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Old 01-23-2014, 07:22 AM   #9067
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one question: Valve checks??
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Old 01-23-2014, 08:48 AM   #9068
BykBoy
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Quote:
Originally Posted by Tafella View Post

one question: Valve checks??
?
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Old 01-23-2014, 09:56 AM   #9069
Jonasson
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Location: Sweden
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Quote:
Originally Posted by GVWR View Post
Today I replaced my tomtom rider with my iphone 5 on my Adventure 1190 R.

The phone has a lifeproof nuud case. That case is waterproof without screenprotector which gives a great picture. And I'm also using the lifeproof bike mount to mount it on the KTM nav mount (which I had to modify a bit).

For charging I'm using a 12v cable from the on board outlet. I also some adhesives to put on my gloves so I can use they screen with gloves on. LEt's wait and see how that works. I've seen some Rukka now has some gloves that have that as standard.






Any pictures of this that works?
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Old 01-23-2014, 01:50 PM   #9070
Tafella
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Quote:
Originally Posted by BykBoy View Post
?

What I wanted to ask is: is the abs unit easy to remove if the valves have to
Be checked or when you need to replace the sparkplug?
What i want to know is : are the brakelines and wiring harnas long enough
To lift the unit when you need to go there for maintenance? Or do you have to
Loosen the brakelines every time?

Cheers
Richard
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Old 01-23-2014, 02:53 PM   #9071
BykBoy
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Joined: Aug 2003
Location: Reston, VA
Oddometer: 528
Quote:
Originally Posted by Tafella View Post
What I wanted to ask is: is the abs unit easy to remove if the valves have to
Be checked or when you need to replace the sparkplug?
What i want to know is : are the brakelines and wiring harnas long enough
To lift the unit when you need to go there for maintenance? Or do you have to
Loosen the brakelines every time?

Cheers
Richard
Got it. The stock lines from the front brakes are long enough. The rear lines are custom made. I made mine 5 inches longer than the stock lines. They are long enough to allow removal of the unit from the doghouse without disconnecting the lines. The fit is tight, but it can still be done. Another inch or two longer will make it even easier. Once the ABS unit is out of he Doghouse, it can be removed in less than a minute.
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Old 01-23-2014, 02:57 PM   #9072
EZ300
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Changed gearing to 16-45 and threw the Mefo back on the bike

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Old 01-23-2014, 03:00 PM   #9073
KamLeeR
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Location: Valley Mills, Texas
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Quote:
Originally Posted by EZ300 View Post
Changed gearing to 16-45 and threw the Mefo back on the bike



What a nice clean chain!
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Old 01-23-2014, 06:13 PM   #9074
Mr Head
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I filled mine with gas on my way home from work, cracked the throttle and stepped the rear out on my favorite turn. Then practiced my wheelies off the bump at the bottom of my hill.

The usual.
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Old 01-23-2014, 09:41 PM   #9075
Lurkerlou
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New boots :)

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