KTM Rally blog

1 Апр 2015 | Author: | Комментарии к записи KTM Rally blog отключены

How to build a Rally bike

In will see how I build motorcycle. Not from scratch, but a solid basis: a brand new motorcycle. As you will see the modifications are and the number of tailor made to. On the internet you will find a of professional rally bike (such as Meca’System and Rally-raidproducts) and a number of people on forums who tried to do it themselves.

I like to my version with everyone who be inspired to build there own bike.

The Bike: KTM 690 Enduro R

It all with a solid basis for the the bike. I choose the KTM 690 Enduro R for its of power and durability whilst being relatively looked at the KTM 530EXC for it’s but this bike would a larger fuel tank -in combination with other it missed in standard configuration- add so much weight the difference the 690 was reduced to only 13 kg.

So here it is, the new bike.


What to do? to start? So many options… I I wanted a high rally to be able to enjoy the protection the wind on long and fast

Furthermore the roadbook holder, navigation and digital instrumentation all behind the fender. Nobody something like that, so the option was to custom built it my

Lucky enough a friend of owns a KTM 690 RR Factory replica I used to copy some parts. motorcycle is far too heavy for technical and rally stages due to the almost fuel capacity. My version of the KTM 690 need extra fuel because it runs over on the standard tank in competition

On the road it will be able to up to 250km on the same 12 liter After the bike was finished, I the 2010 Dresden Breslau, the autonomy was sufficient. See how the bike was build and a look at the details.


I purchased the fairing from an guy called Alberto Dottori it looked good and it was relatively When I finally got it, cheap was the thing it was; the shape was it didn’t fit properly and Mr. Dottori use any gel coat, so it was full of small and impossible to paint.

What a After redesigning the points of the bike, I ended up making a to be able to make my own fairing. a distance it looks the same but it believe me.

  I changed the way it is attached to the bike and used quick locks the KTM factory rally bike. The light (a halogen version the old 690 Enduro model)  is fitted to the Here you see the first fitting of the on the bike:

Welding the frame:

If you a closer look at the KTM 690 Factory bike, you will see a support is welded to the steering head of the This piece of metal the rally tower, a light-weight, and good-looking part which is out to fit the instruments and bear the fairing head light. I used for this part to match the Molybdenum steel of the bike’s The actual welding was commissioned to a company.

The complete bike was at the front and all wiring, CDI, and sparkplug were disconnected. The destroyed my frame number the number was only smashed the paint, not into the steel. It was a lot of and it took some precise but after painting it looked this:

Rally tower and support:

All including a toolbox would be on the rally tower. The incorporated would have to provide at race speed and are therefore a mix of OEM and specially made parts. It me a long time to figure out to put everything.

The Dakar Rally always have the Sentinel and which are mounted on top of each on the handlebar. The roadbook holder is placed in a very high This will increase the and is necessary to be in line with the Downside is the higher point of and vulnerability in case of a crash. I to have the Roadbook, ICO and KTM instrument on and a separate spot for the GPS on top op this.

holders are rubber damped. The tower also holds the with rubber dampers on side. Mounted together the fairing it looks like

The standard bike has two accessory 12v behind the headlamp, one after and one continuously powered. I used and wired them to a fuse box four fuses. Roadbook ICO, GPS and 12v socket are powered and separately.

The road book holder and ICO are to a combo remote on the left of the The original light switch indicator switch) is changed for a CEV switch. I also fabricated a map to adjust the throttle mapping.

self made electronic is connected to the socket under the where the original mapping was located. Now I can change the mapping unfortunately still not ‘on the fly’;  the CDI has to “read” the resistance when the is tuned on.  On the right of the placed the remote switch for the KTM For rally purpose an extra (same as the KTM 450 factory rally) was on the rear fender.

By using a it was possible to get it operated properly. but not least the sidestand safety was disconnection by fitting a KTM powerparts and connect it to the switch wire. never disconnect or bridge the switch, the bike will it runs idle and runs on a mapping.

Engine and exhaust:

is not much you can do to improve the engine of the I replaced the paper air filter a large foam filter and to upload a special open-air This was also necessary for the to deal with the new exhaust. I the standard exhaust because it was heavy and also dangerously

The new stainless steel one is quit, and cool.

Other modifications:

new switch for one that starts at 88C in of 105C to prevent the engine overheating in arduous conditions.

new tank filler cap with on aluminum neck from products UK

Scotts/Ohlins steering for stability in sandy conditions,

Machine USA 2 inch handlebar riser,

rally grips,

Acerbis spoilers on the guards,

PHDS: progressive damping system


Touratech crash bars to the radiators,

Flatland Racing USA engine guard,

Touratech cylinder guard,

clutch to protect the slave cylinder in of a broken chain,

brake cable (brake snake),

the horn,

replaced the wheels for and narrower Thalon wheels excel rims and aluminum

lost the indicators, mirrors and number plate holder,

the seat with leather

…. and more: details, details,

How does it cope in a 8 day rally extreme conditions?

Remarkably I have to say. Of course I to solve some issues attending to the rally, after appeared during one day events. a bad crash the aluminum bar riser piece that holds my damper) was bended badly and my was cracked.

So I will need to a spare bar riser, some tape and I will be fine. ran out of gas, no mechanical problems; change the air filter (browncoal in Poland are pretty nasty and check the oil level. Here you can see me in during the Breslau 2010

KTM 450 Rally
KTM 450 Rally
KTM 450 Rally
KTM 450 Rally
KTM 450 Rally
KTM 450 Rally


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