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The Mod Squad
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2,613 Posts
Discussion Starter #1
I've been pondering this issue for months.

At first I thought I had hit a brick wall.:damn:

But then one day surfing flea-bay... it hit me. There in front of me was the part that would bring it all together. A 300mm KTM brake disc. OMG! :arsenal I thought they were all 260 or 320. I had asked around and no one knew of such an animal.

So after buying back all the parts I had sourced the first time...

I have "dry" fitted the wheel and caliper assy. Easy as pie! All the parts work and line up perfectly! WAHOOOOO!!!!!!

Here it is:




I'm choosing what I believe is the easiest cleanest route. Only one special part needed and no machining or grinding stock parts! My set-up will have a seperate caliper/hose/master/switch set-up that I swap when changing wheels. This way, I take advantage of the "softer" brake feel of a two pot caliper and the smaller/lighter disc, and a matching master.

Here is what this method takes for the front wheel:

A late 90's Adventure 300mm brake disc (used) 45.00
A Ducati Caliper (Monster 620/Sport 1000/Paul Smart) 45.00
A Master from any 2-pot KTM including the brake line 100.00
Brake switch if doesn't come with the above master 30.00
6"x6" piece of aluminum plate (5mm thick) 10.00
Total: 230.00

The brembo caliper and Adventure disc bolt right up. You just need to make a spacer out of aluminum plate. I copied the stock 10mm thick one (actually Gethro down under did it for me). As an alternative, you could just make thick "washers". 5mm isn't enough offset to really worry about shear loading your disc bolts (Inset legal disclaimer BS here). The 5mm spacer(s) go behind the disc in the same place as the stock spacer on the 17"er.

I'm stoked! Finally a clean way to do this!

Hope you guys find this as great as I do..... :twofinger
 

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The Mod Squad
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Discussion Starter #2
I fitted everything up and went for a ride last weekend. Everthing works great.

I did notice that the Ducati caliper and the KTM caliper off the dirt bikes are identical except for the hanger/bracket. I suppose you could source just the bracket but it would likely be more expensive than a complete used caliper.

Also, the brake light switch was 61.00 with shipping. Ouch. If you are gonna go this route, when you source your parts, get a master with the switch already on it. The one I got from Munn's plugs right into the factory harness just like the stock one.

The front brake line could stand to be longer. I have found that the dirt bike version is shorter than the street legal version. So if you get the master with the brake switch and hose/caliper as an assempbly, you should also be getting the longer hose. The shorter one woks fine, but is a little tight across the instrument panel.
 

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all ya have to do is mate it up with a low flowing master 11mm or smaller if possible
and it should be alright
good grab but not to much
Great job
 

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The Mod Squad
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2,613 Posts
Discussion Starter #6
Blome said:
Awesome, but that's still a whole lot a brake for the dirt.
Naw, It really isn't. The brake master is off a 525 (10mm). And the disc is only 300mm, which is about 1" more in leverage (+2" dia) to the 525's 260mm disc.

But the real kicker is weight. The 625 is something like 75lbs(?) heavier. So the brakes are actually just about right. I think I still have a pinch of air to bleed, but it works pretty well.

Same set-up on the late 90's Adventure I think. Or did they use a dual disc?
 

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The Mod Squad
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Discussion Starter #7
Brembo Supplier

A local bike shop gave me the name of the Brembo importer. You can order what ever you need directly from them.

Ducati wanted 400 bucks for the caliper new. These guys wanted 182.00. Prolly a good resource for any Brembo parts ya need. I forgot to ask what a radial master cyl would cost.

TAW concepts in Colo: 888-235-0910
 

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The Mod Squad
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Discussion Starter #8
Ride Report

WOW!

With the dirt set-up this bike is a totally different animal! And it's taller than fark!

The dirt set-up raises the bike about an 1-1/2". And the front (with my tire choices) raises about 5/8" more than the rear.

You can REALLY feel the difference in rake/trail/21" right away. I've only had a chance to ride pavement, but you can immediatly tell this thing wants DIRT! The set-up has you climbing right up on the tank. The front end makes you feel like you want to spin the rear tire out to the side. I'm gonna have a dirt oportunity this weekend.

I'll report more then!
 

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The Mod Squad
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Discussion Starter #9
I've been getting quite a few questions about this set up from the various sites it's posted. So I thought I'd share some parts sources to make things easier.

Look for the caliper on:

http://www.ducatimonster.org/

or:
http://www.ducati.ms/forums/index.php

Look for the KTM parts here:
http://ktmtalk.com/

or:
http://www.advrider.com/

And if all else fails... don't forget fleabay.

I have been riding with this set-up alot. Infact, I hardly ever run my SM set-up, just because the whole dirt world is "new to me" again after riding street bikes only for 30yrs.

I have on occasion had to grab a whole lotta front brake. :eek: And the set-up works great. On dirt it will lock up the front wheel. I haven't had the need or desire to try locking it up on pavement, but since i'm running a knobbie, I'm sure it wouldn't be a problem.
 

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nice work pazzoduc. do you have any pics showing the whole bike? i'm curious to see what it looks like. i own an '05 smc625 btw.
 

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A local bike shop gave me the name of the Brembo importer. You can order what ever you need directly from them.

Ducati wanted 400 bucks for the caliper new. These guys wanted 182.00. Prolly a good resource for any Brembo parts ya need. I forgot to ask what a radial master cyl would cost.

TAW concepts in Colo: 888-235-0910
I get all my Brembo stuff from Fred Renz @ www.yoyodyneti.com . He has a good web site with some supermoto stuff added, lots of Brembo OEM spares, and Fred is the man too talk about Brembo parts. He REALLY!!! knows his stuff.
 
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