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Old 02-05-2014, 08:41 AM   #1861
Goofy Footer
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HDB hdpe triple clamp setup

Quote:
Originally Posted by theantipaul View Post

The triple mounts are 1/4" and have no problem holding all the weight of lights and nav gear.

I too am interested in these hdpe triple clamp mounted units. I'd like to use it as a dualsport fairing and this looks like a great option to switch between bikes (bikes set up with the top clamp brackets). This way I could have one bitchen adventure / night riding package instead of buying nice lights for each bike.

I like that the new design is simpler and doesn't require the bottom clamp. I like that it is hdpe too. The first rallye lite design incorporated a bottom bracket that bolted into KTM/Husaberg's bottom triple clamp and required WR/CRFs to drill/tap the front fender bolts through the top clamp so the bottom bracket could mount there. When Paul says the latest design is strong, I damn well believe him!



Deadly99, I too have a steel frame WR (2005) and your bike looks Great!







For the guys running the HDB hdpe setups, any additional pics/info/insight would be bomb!

Thanks in advance!
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Old 02-05-2014, 12:21 PM   #1862
Happe
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Originally Posted by 640 Armageddon View Post
Don't shoot the messenger
Sometimes in the price of an add on you have to take into account the present that you need to get her in order to make things even again
Wise words,
it wasn't the Rally Light Kit, it will be her new shoes that break the bank ....

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Old 02-05-2014, 12:28 PM   #1863
Happe
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Quote:
Originally Posted by Goofy Footer View Post
I like that the new design is simpler and doesn't require the bottom clamp. I like that it is hdpe too. The first rallye lite design incorporated a bottom bracket that bolted into KTM/Husaberg's bottom triple clamp and required WR/CRFs to drill/tap the front fender bolts through the top clamp so the bottom bracket could mount there. When Paul says the latest design is strong, I damn well believe him!
I well like that lower bracket. It gives the perfect place to secure the brake line and speedo cables.
In the Kit you have even the necessary P-Clips

Stefan
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Old 02-05-2014, 02:07 PM   #1864
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A lot to catch up on, and right now just finished up with a meeting and we're in the middle of shipping, so here are some pics of the install I haven't finished yet for the site. Hope it will help. Sorry for the photo dump, will edit this tonight.




















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Old 02-05-2014, 02:12 PM   #1865
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Then when you pull off the frame mounted assemblies the frame mount stays and the triple mounted can go right on.







Here's what it's like with it on my bike,

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Old 02-05-2014, 02:15 PM   #1866
Baja Dad
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Very nice paul !!!!
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Old 02-05-2014, 04:38 PM   #1867
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Uh Oh........looks like you finally got around to building what I need for my 640......nice work Paul!

Cheers
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Old 02-06-2014, 08:36 AM   #1868
mountaincadre
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Me too Paul when will it be available, must havey, must havey. this is what I was on about when I e-mailed your good self last week.
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Old 02-06-2014, 08:57 AM   #1869
Goofy Footer
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Brake Line Routing

Quote:
Originally Posted by Happe View Post
I well like that lower bracket. It gives the perfect place to secure the brake line and speedo cables.
In the Kit you have even the necessary P-Clips

Stefan
Do the P-Clips hold the brake line steady or allow for travel? I ask because I'm interested in where the line takes up the slack from when the suspension compresses - I've never seen the line routed that way so I'm curious.

Thanks for the pic and info!
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Old 02-06-2014, 09:01 AM   #1870
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Quote:
Originally Posted by Goofy Footer View Post
Do the P-Clips hold the brake line steady or allow for travel? I ask because I'm interested in where the line takes up the slack from when the suspension compresses - I've never seen the line routed that way so I'm curious.

Thanks for the pic and info!
they need to hold the line tight
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Old 02-06-2014, 09:34 AM   #1871
drc42
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Quote:
Originally Posted by Goofy Footer View Post
Do the P-Clips hold the brake line steady or allow for travel? I ask because I'm interested in where the line takes up the slack from when the suspension compresses - I've never seen the line routed that way so I'm curious.

Thanks for the pic and info!
This is a typical way to route the brake line on a rally bike. There is a danger of the line looping around your nav gear if you let the slack get taken up by the handlbars like on a typcial dirt bike. So, what most people do is strip off the rigid plastic on the line, clamp it tight like you see here, then let it flex out to the side as the suspension compresses.
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Old 02-06-2014, 09:53 AM   #1872
DaveRMS
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There is also a complete routing writeup here: http://rallymanagementservices.com/p...rally-fairings

We also recommend wrapping the sensor cable to the brake line using spiral wrap. It provides protection and also doesn't pinch the cables. Be careful using zipties.

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Old 02-06-2014, 12:43 PM   #1873
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I guess in high speed rallying, there is very small risk of that big loop of brake line sticking out to the side to be caught on something... But what about normal riding, wouldn't that be a significant risk?

PS. "Careful with zipties" - what is the danger here?
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Old 02-06-2014, 01:13 PM   #1874
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Quote:
Originally Posted by Bli55 View Post
PS. "Careful with zipties" - what is the danger here?
pinching the cable and creating hotspots on the sheath, and even the wiring through the sheath.
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Old 02-06-2014, 01:46 PM   #1875
Happe
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Quote:
Originally Posted by Bli55 View Post
I guess in high speed rallying, there is very small risk of that big loop of brake line sticking out to the side to be caught on something... But what about normal riding, wouldn't that be a significant risk?

PS. "Careful with zipties" - what is the danger here?
On my first Roadbook tour with the EXC in 2012 the brake line wound around the Roadbook and almost caused me losing control and crash.
After that I re routed it the way as used on my 660 Rally Replica, same way as you see here and what all the Rally bots recommend.
Since them I rode all different kinds of terrain from dried river beds to french/slovenian forrest trails with the occational trip into the deep shrubbery
Never had an issue with the brake line catching.
It doesn't stick out further than your knees or handlebar.


cu
Stefan

Happe screwed with this post 02-06-2014 at 02:02 PM Reason: added picture
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