2012 ktm 500 exc?

[harcus]

Originally Posted by Geek

It's a rally cockpit... giving you lots of space for roadbooks, gps's, etc.. as well as giving you lots of lighting options.

All pieces are aluminum (anodized black) and the thing is amazingly strong (as witnessed last Wednesday when I watched Paul cartwheel his bike end over end )

As you can see in this photo, the bar risers actually bolt with 4 12mm bolts to the upper triple clamp making them incredibly stout:


Between the risers (of which they have different heights available) you can see the adjustable damper mount



The system is designed so that you can run one headlight, or two. You can run it with your stock fairing or a rally fairing (which they don't have done yet). For now I'm going to replace my stock headlight with a single Squadron unit and get rid of the pathetic excuse for a stock headlight; then I'll consider going with two squadrons or maybe a stryker and a squadron after they have the full fairing available.


Either way... I'm excited about doing some night riding now instead of fearing it with the stock candle

The squadron mount has a precise fit spacer with an boss built in for the anti-slip ring. You torque it down tight, the ring is made to crush out the right amount:


Here you can see I have the squadron mounted in the middle hole in the bottom location. Both mounting locations have 3 different mounting points giving lots of adjustability/tuneability depending on what you are using for lights


This is the backing plate for the squadron that allows mounting it to my stock 500's headlight mask


This spacer/re-enforcement ring is aluminum






Lots of cockpit space for roadbook, etc




...to be continued.

Those are beautiful parts, Geek. Lot's of NC time in there. Did you say they came from HDB?

[LukasM]

Originally Posted by harcus

Those are beautiful parts, Geek. Lot's of NC time in there. Did you say they came from HDB?

Yup, HDB. Fantastic design and production as usual from Paul. There is a thread on "rally navigation brackets" in the Racing subforum, he developed the design based on feedback from the experienced racers on there.

[Mifune]

Originally Posted by LukasM

Yup, HDB. Fantastic design and production as usual from Paul. There is a thread on "rally navigation brackets" in the Racing subforum, he developed the design based on feedback from the experienced racers on there.

Looks like the fairing/roadbook/light support brackets would sandwich right in for those of us who already have the standard HDB installation. Is that right?

[theantipaul]

Originally Posted by LukasM

Yup, HDB. Fantastic design and production as usual from Paul. There is a thread on "rally navigation brackets" in the Racing subforum, he developed the design based on feedback from the experienced racers on there.

Thanks Lukas, coming from you that means something. Crankshaft and Pilo helped a lot with the design going back and forth over the phone and emailing drawings.

Originally Posted by Mifune

Looks like the fairing/roadbook/light support brackets would sandwich right in for those of us who already have the standard HDB installation. Is that right?

Yes, but the standard top clamps wil need to be modified for the rider side M10 bolts, so I'll exchange that part for anyone that already has the guards.

Originally Posted by harcus

Those are beautiful parts, Geek. Lot's of NC time in there. Did you say they came from HDB?

Thanks Harcus, It's not quite done so they're not on the site yet. It needs some refinement and I start on the fairing mold this week.
When all that's done I'll post up in Vendors for anyone interested.

[toddler]

The tank is a bit skinnier than the stock tank with shrouds.



First thing I noticed was a clearance problem with the Enduro Engineering radiator guards.



A simple bend of the radiator mount relieved that issue. You may not want to do this. I'm okay with it.



The second issue was up near the top of the radiator guard. It was rubbing against the tank. So I filed down the radiator guard so the surface was smooth and not a sharp edge.



The pump dropped in very nicely and the two new mount bolts below aligned well(you reuse your old o-rings) and everything snugged up very well. The screws for mounting the electronic portion should NOT be tightened very tight. Be careful here. They say 2ft/lbs of torque.

It is wider across the thigh for sure.



The tank to plastic area has a gap.



But overall I'm going to enjoy the range.





Acerbis did a very nice job on this tank.

Now I need to go for a ride!

[Geek]

So I got up early to get some wrenching in before we head up hiking in the mountains for the day... I wanted to get a mental grasp on what types of things I am still going to have to work out.. like wiring (yay! I have room to mount my horn ) brake line routing, etc.

Here's a bunch more pics...





Here's what makes this design so stout...
notice our triple clamps have two holes on each side (I took this photo last night when doing a spring swap)


Paul has designed his system so that the center bolts go through the risers like normal...


..but instead of the rear top clamp just bolting the clamp down, it goes all the way through and into that second triple clamp bolt meaning the entire system is bolted to the top triple with four 12mm bolts instead of two!





Since I already have the HDB system for crash guards and top clamp installed on my bike; everything bolted straight up quickly

[Geek]

Looking at the tree...

Looking down from the top - you can see how the tree mount extends in front of the HDB instrument guard


The bottom of the tree goes in with two bolts to the existing holes in the lower triple


The top of the tree mounts up with four bolts


test fitting - everything aligns perfectly.

[Geek]

Roadbook system.

A big reason for me installing this is for Roadbook usage. The thing is, sadly that is only a small percentage of seat time.

...so for me the system has to 1) work and 2) be easy to remove!

The roadbook installs on the machined tower sticking up from the top


Here you can see how the mounting bracket on the f2r wraps around the pivot


Then another machined clamp and 4 nuts and its mounted - obviously easy to adjust the viewing angle.




With stock headlight mask




...then here is the cool part... 4 bolts (the tower bolts - not the roadbook's rotation bolts)... and in under a minute:


the entire thing comes off. I'm going to come up with some sort of a bracket that goes across with a RAM ball so I can mount my GPS in the space.



Now I'm back to regular "dirtbike" mode.



btw.. the mount for the roadbook has multiple mounting holes so you can fine tune how high or low you want your road book to be.



Combine that with all of the holes in the frame (the 6 holes by my thumb).. and you can fine tune the roadbook to exactly where you want it.


If you want the roadbook further forward, just move the re-enforcement brace to the rear.


Overall I'm impressed with how well thought out this solution is.

Now I just gotta figure out my part of the equation.. how I want my brake line routed, my wiring loom positioned, etc.

[Geek]

That looks awesome!

Have a pic of the left side? How big is the bulge where there's no exhaust pipe?

[Mifune]

Hey Geek, thanks for the detailed write-up and photos of the HDB rallybook mount. I'm about halfway through the thread over here (http://www.advrider.com/forums/showthread.php?t=684282) where Paul's ideas took shape. That's also a fascinating read and I can't wait to get to the part where he reconsiders whether to mount to the frame or to use his existing topclamp. My interest will be mainly for the robust lighting and fairing mounting poins - so the fact that I don't need a rallybook also makes being able to remove it an advantage.

Looks like I'm just a couple of days behind you in mounting the 5.3g tank. So thanks also for sharing those pictures.

-Stuart

[toddler]

Mock up shot in the garage will give you an idea of the left side.

[SteveO]

Originally Posted by toddler

Mock up shot in the garage will give you an idea of the left side.

So have you had a chance to ride any trails with this super-tanker mounted up? I'm curious about the handling....

[cross-country]

Originally Posted by toddler

Mock up shot in the garage will give you an idea of the left side.

The tank looks alot better in Natural! Now I want one! I see you also got a damper on the bike finally. Neccesity? or was it just that pretty HDB submount taunting you that made you decide to mount one?

Sorry to hear about the fuel pump. EFI is the debils work! What did your 10 micron filter look like when you pulled it? What about the internal filter?

I assume the internal filter is before the pump?

Did you buy one of these? http://www.ca-cycleworks.com/fp-hus (edit:this may not be a replacement)

You're bike problems are affecting my riding plans now, so let's get it fixed quick, m'Kay?
chop. chop.

[toddler]

Originally Posted by cross-country

The tank looks alot better in Natural! Now I want one! I see you also got a damper on the bike finally. Neccesity? or was it just that pretty HDB submount taunting you that made you decide to mount one?

Sorry to hear about the fuel pump. What did your 10 micron filter look like when you pulled it? What about the internal filter?

I assume the internal filter is before the pump?

Did you buy one of these? http://www.ca-cycleworks.com/fp-hus

You're bike problems are affecting my riding plans now, so let's get it fixed quick, m'Kay?
chop. chop.

The HDB stuff taunted me into the damper, I'm not sure the bike needs it except for the full throttle open stuff. I suppose not falling in that situation is preferred

Here is a pic for you of the filter closest to the injector. I blew through it and it had significant resistance compared to the new 20 filter. I'm not sur the picture shows much.



I did not look at the tank filter. I think I will need too.

I'm having a bad month for stuff breaking. Hard drives, laptops, clutch hubs, subframes, fi pumps, cameras, and I don't even want to think about work. All little stuff in the grand scheme of things, but they take time. I'll be back to full scale riding before the end of this month.

[toddler]

Originally Posted by SteveO

So have you had a chance to ride any trails with this super-tanker mounted up? I'm curious about the handling....

Not yet SteveO, my FI pump is not working at the moment. I'll post a review after I can take it out for some testing.