KTM 690 Enduro - Extending the foot peg
Discussion
This seems to be a issue that people other than me have had but I couldn't find a solution so I made one. I did think about 3d printing this part but even though it's probably not going to be as string, it's an option if you don't have a lathe. Hopefully this is of some use to someone.
The problem I was having was that the gear lever on the KTM didn't extend far enough from the bike and I kept missing gears by missing the lever. I couldn't find a lever that extended further from the bike so I modified one.
The lever I had on the bike wasn't the original and had a square profile which would have been more complicated to extend. So I bought an Apico KTM Forged Gear Lever (Reference number:20558) from Dirtbike Express for a 2017 onward KTM EXCF 450 as this will also fit my 2014 KTM 690 Enduro. This lever is a little wider than the one I had but also it has a round hole that would take a extension that I could easily machine on my lathe.
The next step was to buy some ABS plastic round stock. The stuff I bought was 20mm by about 100mm... the length doesn't matter as long as it's more than about 30mm. I didn't want to extend with metal as I didn't want to add mass to the lever or add anything that wasn't sacrificial in a crash. There's always potential for anything like this to increase the damage (to you or the bike) in a crash but this seemed like a sensible material choice.
I then machined the rod down to about 12mm at the narrow end and about 17mm at the wide end. I machined some grooves in the side that inserts in to the lever so I could epoxy it in. The picture shows the insert which is already a bit scuffed as I'd already trial fitted it.
This then inserts in to the lever end. I've glued it in with threadlock so I could get it out relatively easily if I didn't like it or wanted to make it longer. The end result is as follows...
Published on Riders Garage Stories: https://ridersgarage.co.uk/story/extending-the-gea...
Service history logged with Riders Garage
The problem I was having was that the gear lever on the KTM didn't extend far enough from the bike and I kept missing gears by missing the lever. I couldn't find a lever that extended further from the bike so I modified one.
The lever I had on the bike wasn't the original and had a square profile which would have been more complicated to extend. So I bought an Apico KTM Forged Gear Lever (Reference number:20558) from Dirtbike Express for a 2017 onward KTM EXCF 450 as this will also fit my 2014 KTM 690 Enduro. This lever is a little wider than the one I had but also it has a round hole that would take a extension that I could easily machine on my lathe.
The next step was to buy some ABS plastic round stock. The stuff I bought was 20mm by about 100mm... the length doesn't matter as long as it's more than about 30mm. I didn't want to extend with metal as I didn't want to add mass to the lever or add anything that wasn't sacrificial in a crash. There's always potential for anything like this to increase the damage (to you or the bike) in a crash but this seemed like a sensible material choice.
I then machined the rod down to about 12mm at the narrow end and about 17mm at the wide end. I machined some grooves in the side that inserts in to the lever so I could epoxy it in. The picture shows the insert which is already a bit scuffed as I'd already trial fitted it.
This then inserts in to the lever end. I've glued it in with threadlock so I could get it out relatively easily if I didn't like it or wanted to make it longer. The end result is as follows...
Published on Riders Garage Stories: https://ridersgarage.co.uk/story/extending-the-gea...
Service history logged with Riders Garage
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