CURRENT MILES
22,022
Just a short and simple mod today. I’m still working on my big list of things before the Nor Cal BDR and this time it’s putting on the new Tail Tidy.
Technically it’s not a Tail Tidy, it’s an actual KTM part called a Number Plate Carrier (#24).
I had noticed my license plate bobbed up and down. It’s not supposed to. It turns out that I broke the last one because I had modified it too much. I had taken a Dremel to it and carved out some of the plastic to make it fit better. It had then cracked and if I had left it, the license plate might have fallen off on the trail. Not the worst thing but I kind of like the plate I have.
It would have made a super gift if I had lost it on the BDR and someone riding the BDR found it – right?
On the 690 there’s 4 threaded inserts in the top of the gas tank. There are then 4 M8 bolts that fasten this to the tank. IF you have (like I do) a rear top rack, those bolts need to go through the rack, then spacers, then the plastic fender, before finding the inserts in the tank. Add a side rack like I sometimes run and there’s another wobbly bit to get aligned and hopefully drop a bolt in and get it to thread correctly. That’s always been a challenge.
Add to that none of the parts seem to fit each other. Everything is just a little off, especially this Number Plate Carrier. The one thing that doesn’t flex or move is the gas tank.
As I was struggling to put it all together, flexing this one way while flexing that the other… I had an idea. Why not have these as studs instead? Then I could add each piece, one at a time, over the studs and finish it all off with a nyloc?
So I popped over to Amazon and found some Stainless threaded rod in M8 with a 1.25 pitch to match my gas tank inserts. Cheap enough, eh?
I wasn’t sure exactly what length I would need but knew it would be less than 4 inches so cutting these 8 inchers in half would work fine.
When they arrived I did a quick test fit. Yay! They were going to be perfect!
Next I installed one stud in place, added my stack of items to check for thickness (spacers, rack mounts and so on). I marked where I thought the length should be and then cut the rods using my angle grinder. No pictures of this as I had to use all my available hands.
To thread the stud in you simply use two nuts and lock them together. This way I didn’t mess up threads with a clamp or pliers. The same goes for taking them out.
On the back two bolts I couldn’t get an accurate measurement as it’s recessed in the rack so I checked the depth I need for the washer and Nyloc. It was just a hair over 9mm.
I looked for something that I had that I could easily use as a spacer and found out a 13 mm wrench I had was the same thickness.
Using that I could mark where I needed to cut the stud. Easy Peasy. I then put a little Locktite on the stud.
And we were ready to install. I used the same locked nuts to thread it all the way in and then moved on to the next one. When I had all four done I let it dry overnight.
In the morning I cleaned up the cut thread ends a bit and assembled it all.
The rack is usually going to have a big thick Mosko Rackless 80 over the top, but I still need a smooth surface. That stud is just about as close as I can get to a flat plane – although I might file it just a little more.
The best thing is that the whole thing went together with so little trouble. No more fiddling around, no more poking things into alignment with a screwdriver while trying see, while also trying to get a bolt to thread – “Wait! did it just cross thread?” Honestly – it was always quite a struggle!
Now this just stacks one on top of the other, piece by piece and tighten it all down with a nut! KTM doesn’t do this stock as the part is usually not added on to (rack, side racks, etc) except for in the aftermarket.
Honestly, I did guesstimate the front two stud lengths a little too long. They stick up a little too far past the nuts but I checked when I put my luggage on and they are a full 2 inches away from hitting my luggage.
The next time I take it all apart I can trim them shorter – that’s not an issue. But just in case for now… I gave them a little protection.
He's an avid hockey fan, rides a mountain bike, sometimes rides a road bike, has a few motorcycles (he had a really fast one, had a big cool orange one, rode a really slow one, and is currently building a perfect "BDR Weapon"). If that isn't enough, he makes cheese and sourdough bread, loves strong beer and good red wine, and poorly plays the Mandolin.
- My Pre Nor Cal BDR Settings - September 15, 2024
- New Pump, No Pressure, What Did I Do? - September 9, 2024
- Studs > Bolts for the Rear Rack - September 5, 2024
Leave a Reply