When fitting metal parts in tight fitting places such these (and bearings) you can put the inner part in the freezer for a few hours before hand and then grab it just before you want to install it, light layer of grease and it will slide in easier. They are machined to such fine tolerances these days that the cold does just enough to make it fit. Another tip is to very slightly loosen the brake and clutch clamps, so when the bike goes over the whole assembly moves to take the force off the levers. It needs to be tight enough to stay in place but just loose enough so you can move it slightly by tapping your palm on it firmly. Another way is to put some electrical tape under the clamp which gives way in an impact allowing the assembly to rotate on the bar a little. Happy adventuring!
Amazing tips Tom- thank you- they all make total sense! I have used the freezer trick for metal parts before for other things, but stupidly I didn't think to use it on this even though I made reference to it in the video! Really appreciate your contribution and advice. Thanks for watching.
Thanks. Noobie on the 890 also. Cut my teeth fifteen years ago on the air cooled r1200gs and then the water cooled model, but found them too heavy for what I am trying to do now. Looks like I will have to order those KTM grips. I like the folding part, but especially like how they can be adjusted to a shorter length which hopefully will make two and three finger grip transitions easier. Just subscribed.
Hi Alb. I did do some film of the clutch install but I didn't want to make the video any longer. The clutch lever is really simple compared to the brake. It's just inserting a pin made captive with an E clip. It was very straightforward- just make sure you don't drop the clip down a drain when it pings off!! Thanks for watching.
When these bikes are parked, a lotta care needs to be taken the bike isnt too straight up and down................there are ways they can fall and land where its really hard to get them back up..........the headlight is 1200.00 for an 890R...............Food for thought................with real alu dirtbike handguards Ive never once broken a lever. Many crashes on dirt with actual dirtbikes...
I bought the same levers as part of my initial purchase of the bike. It wasn't until I tried to install them, like 'Noobie above, that I realized what a sh!t design they are. Instead of making simple "plug-n-play" levers, the idiots at KTM decided to make them multi-piece levers, where the part that interfaces with the perch is actually a separate piece, which means, as shown, to assemble the right (brake) lever, you need an arbor press or hydraulic press to get that bushing out, separating the 2 OEM pieces, then you need to press the OEM inner piece together with the Power Parts outer lever using a new bushing. WAY more complicated than it should be especially because nobody I know, and I'm in the Mechanical Design field, HAS a press in their garage. I had to take it to the dealer to install it, and they charged me 1/2 hr labor. Oh, AND realize that these levers were about $300USD!!! I mean, they're beautiful levers, but, like everything else on the bike (my 890 is a TOTAL PITA to add parts to), it's poorly designed and overly-complicated. Glad I put them on, but, C'mon KTM, give us a break!
Hey KX and great opinions and feedback. I agree it was more complicated than expected for the brake. I’ve had years of maintaining boats so had some tricks to fall back on. I do t have a press or even a workshop for that matter, but did manage it- just. Thanks for watching.
@@advnoobie6061 Hey, good to hear from ya! I got my 890 R in Jan of 2021. So far I put the aforementioned levers on, the OEM centerstand (it was better quality than aftermarket), the KTM sidestand "big" foot, the Vanasche GPS mount with a Garmin Zumo XT (getting to the wiring in the headlight was a total PITA), a set of SW-Motech Pro (quick-release) carriers, aluminum panniers and top box, a SW-Motech Pro Daypack Tankbag (you can just flip the mount on the bottom of the bag 180deg instead of having to mount the whole tankbag backwards) and the Tripleclamp headstock braces. Also, a Puig Sport Screen (had to order the orange from Italy, nobody in the US had it - helps with the buffeting), and a set of the KTM orange aluminum/plastic handguards (made by Barkbusters, and recently a set of KTM "NEKEN" bars for a 2015+ EXC/XC-W (Part no 7800200100030) because I wanted a flatter bend. That ALSO was a PITA, because I had to try and find a balance between interfering with my tankbag the least, and NOT hitting the dashboard at full lock. I have yet to put on the Sargent seat (in transit) and Arrow cat-delete midpipe and can (with spark arrestor). First I have to mount the Touratech Rallyform skidplate which I bought because it's the ONLY skidplate I know of that works with the OEM centerstand, AND has replaceable plates that protect the sides of the tank like the OEM plastic guards do. So, I can post up on the install of the Arrow stuff and the skidplate if you like. Hopefully it won't be TOO much of a PITA. Ride safe!
@@advnoobie6061 Oh, and this won't help REMOVE that bushing, but for installing it, you can take a long bolt that is just slightly smaller than the ID of the bushing with some thick fender washers and a nut, thread the bolt thru the bushing with washers under the head of the bolt and under the nut, and simply tighten the bolt. A press is way better and faster and you can press out the bushing as easily as you press the new one in. I paid the shop to do it because I didn't feel like f@cking around with it. Oh, and I ALSO forgot to put that little spring back in, but on the clutch side. Doh! I was able to CAREFULLY remove the circlip and put the spring in, and put it back together again, and so far it seems to be holding just fine. Best of luck with your build!
I have the upgraded handguards purchased now and am trying to order those same levers. I guess those levers, may not necessarily have helped in this specific situation since it hit and bent downwards?? But, hopefully should help in other scenarios.
Hi Allen- you are absolutely correct and I only worked that out after watching the film back. Good spot!! I think these levers would have helped because they are shorter and therefore probably would not have impacted.
If I remember correctly the levers will pivot either direction, and are adjustable for length (how many fingers on the lever) and reach. Nice levers, but p@ss-poor complicated design and EXPENSIVE. But, I wouldn't buy that cheap chinesium crap, so...
I asked the guys at Sweet Lamb about this and they said the 890r doesn’t need extra crash bars. I’ve done more research and most people seem to think not needed as well. The tanks are designed to take a lot of force and the plastic covers on the tank do all the scrape protection. Check out my video on mods.
When fitting metal parts in tight fitting places such these (and bearings) you can put the inner part in the freezer for a few hours before hand and then grab it just before you want to install it, light layer of grease and it will slide in easier. They are machined to such fine tolerances these days that the cold does just enough to make it fit. Another tip is to very slightly loosen the brake and clutch clamps, so when the bike goes over the whole assembly moves to take the force off the levers. It needs to be tight enough to stay in place but just loose enough so you can move it slightly by tapping your palm on it firmly. Another way is to put some electrical tape under the clamp which gives way in an impact allowing the assembly to rotate on the bar a little. Happy adventuring!
Amazing tips Tom- thank you- they all make total sense! I have used the freezer trick for metal parts before for other things, but stupidly I didn't think to use it on this even though I made reference to it in the video!
Really appreciate your contribution and advice. Thanks for watching.
WD40 or silicone grease works perfect on these parts.
Love your content good sir! Just picked up an 890 R last week. Thanks for the tips! Sure wish I had your scenery to ride in! Keep it coming!
Thanks. Noobie on the 890 also. Cut my teeth fifteen years ago on the air cooled r1200gs and then the water cooled model, but found them too heavy for what I am trying to do now. Looks like I will have to order those KTM grips. I like the folding part, but especially like how they can be adjusted to a shorter length which hopefully will make two and three finger grip transitions easier. Just subscribed.
Nice and thanks for watching.
Thanks for the video! I plan to do the same install myself. Great if you showed the clutch install. Cheers.
Hi Alb. I did do some film of the clutch install but I didn't want to make the video any longer. The clutch lever is really simple compared to the brake. It's just inserting a pin made captive with an E clip. It was very straightforward- just make sure you don't drop the clip down a drain when it pings off!!
Thanks for watching.
When these bikes are parked, a lotta care needs to be taken the bike isnt too straight up and down................there are ways they can fall and land where its really hard to get them back up..........the headlight is 1200.00 for an 890R...............Food for thought................with real alu dirtbike handguards Ive never once broken a lever. Many crashes on dirt with actual dirtbikes...
Thanks Brad. Appreciate the feedback.
I bought the same levers as part of my initial purchase of the bike. It wasn't until I tried to install them, like 'Noobie above, that I realized what a sh!t design they are. Instead of making simple "plug-n-play" levers, the idiots at KTM decided to make them multi-piece levers, where the part that interfaces with the perch is actually a separate piece, which means, as shown, to assemble the right (brake) lever, you need an arbor press or hydraulic press to get that bushing out, separating the 2 OEM pieces, then you need to press the OEM inner piece together with the Power Parts outer lever using a new bushing. WAY more complicated than it should be especially because nobody I know, and I'm in the Mechanical Design field, HAS a press in their garage. I had to take it to the dealer to install it, and they charged me 1/2 hr labor. Oh, AND realize that these levers were about $300USD!!! I mean, they're beautiful levers, but, like everything else on the bike (my 890 is a TOTAL PITA to add parts to), it's poorly designed and overly-complicated. Glad I put them on, but, C'mon KTM, give us a break!
Hey KX and great opinions and feedback. I agree it was more complicated than expected for the brake. I’ve had years of maintaining boats so had some tricks to fall back on. I do t have a press or even a workshop for that matter, but did manage it- just.
Thanks for watching.
@@advnoobie6061 Hey, good to hear from ya! I got my 890 R in Jan of 2021. So far I put the aforementioned levers on, the OEM centerstand (it was better quality than aftermarket), the KTM sidestand "big" foot, the Vanasche GPS mount with a Garmin Zumo XT (getting to the wiring in the headlight was a total PITA), a set of SW-Motech Pro (quick-release) carriers, aluminum panniers and top box, a SW-Motech Pro Daypack Tankbag (you can just flip the mount on the bottom of the bag 180deg instead of having to mount the whole tankbag backwards) and the Tripleclamp headstock braces. Also, a Puig Sport Screen (had to order the orange from Italy, nobody in the US had it - helps with the buffeting), and a set of the KTM orange aluminum/plastic handguards (made by Barkbusters, and recently a set of KTM "NEKEN" bars for a 2015+ EXC/XC-W (Part no 7800200100030) because I wanted a flatter bend. That ALSO was a PITA, because I had to try and find a balance between interfering with my tankbag the least, and NOT hitting the dashboard at full lock. I have yet to put on the Sargent seat (in transit) and Arrow cat-delete midpipe and can (with spark arrestor). First I have to mount the Touratech Rallyform skidplate which I bought because it's the ONLY skidplate I know of that works with the OEM centerstand, AND has replaceable plates that protect the sides of the tank like the OEM plastic guards do. So, I can post up on the install of the Arrow stuff and the skidplate if you like. Hopefully it won't be TOO much of a PITA. Ride safe!
@@advnoobie6061 Oh, and this won't help REMOVE that bushing, but for installing it, you can take a long bolt that is just slightly smaller than the ID of the bushing with some thick fender washers and a nut, thread the bolt thru the bushing with washers under the head of the bolt and under the nut, and simply tighten the bolt. A press is way better and faster and you can press out the bushing as easily as you press the new one in. I paid the shop to do it because I didn't feel like f@cking around with it. Oh, and I ALSO forgot to put that little spring back in, but on the clutch side. Doh! I was able to CAREFULLY remove the circlip and put the spring in, and put it back together again, and so far it seems to be holding just fine. Best of luck with your build!
Good Choice to change That.
Good tips!
Glad it was helpful!
I have the same bike, will get that set of levers!
I have the upgraded handguards purchased now and am trying to order those same levers. I guess those levers, may not necessarily have helped in this specific situation since it hit and bent downwards?? But, hopefully should help in other scenarios.
Hi Allen- you are absolutely correct and I only worked that out after watching the film back. Good spot!! I think these levers would have helped because they are shorter and therefore probably would not have impacted.
If I remember correctly the levers will pivot either direction, and are adjustable for length (how many fingers on the lever) and reach. Nice levers, but p@ss-poor complicated design and EXPENSIVE. But, I wouldn't buy that cheap chinesium crap, so...
@@kx8960 yes, they adjust for length, though I’ve kept them at their shortest and that’s just fine.
@@advnoobie6061 Same here, they seem to fit my hand perfectly.
hello sir, can you tell us what handle guard do you use? looks good 👍🏻👍🏻
It’s Touratech Defensa. I really
Like them. Check out my first mods film.
Thanks for watching and commenting.
@@advnoobie6061 thanks for your info 👍🏻👍🏻
Just leave all the clutch and brake collars not super tight
Good advice and I’ve heard of this. Thanks for watching.
How much were the levers please?
Sorry for the delayed reply- not cheap- about £130 each!
Hello, what you think Crash Bars (metal) for the KTM, is plastic enough for motor and tank ?
I asked the guys at Sweet Lamb about this and they said the 890r doesn’t need extra crash bars. I’ve done more research and most people seem to think not needed as well. The tanks are designed to take a lot of force and the plastic covers on the tank do all the scrape protection. Check out my video on mods.