Push it! Harder, Further, Beyond Limits!
This kit was designed from the ground up to give the 790/890 Adventure S or R unparalleled aesthetics and functionality. The Aurora 790/890 Rally kit is easy to install, and it is designed for long lasting traveling adventures over any terrain. It can be upgraded at anytime to competition performance by the addition of the optional Aurora 790/890 rally parts. More info below...
As always, we do not want to take the fun out of building the kit. We want you to enjoy building the kit with minimal effort. Everything comes pre-assembled and labelled and a manual is there to assist you for your installation.
Seeing is believing...
The head clamp is the most important part of any rally kit that is installed onto a bike that does not have a welded clamp by the manufacturer. It has to be simple, yet strong and it should not affect the bike’s frame at anyway. We firmly believe that you should be able to revert the bike in its original condition, should you want to, therefore the clamp design must be such that no drilling or welding is needed at any point.
As the clamp holds the navigation tower, electrics and electronics, plus some expensive navigation gear (GPS, Roadbook holders, Tripmeters etc.), failure is not an option. Using the OEM tower mounts was not an option as well, as these are known to bend after a fall and/or crack, causing really serious damage to the bike. Our 790/890 head clamp is designed for your safety, as it is developed based on our pioneering 701 head clamp design.
This, new, billet spider clamp is optimized for the 790/890 Adventure, and while it protects the stock mounting points, it uses a U-bolt to keep the clamp firmly on the frame of the bike. Using the latest CAD systems to shave material where it is not needed, this clamp is 35% lighter than the first-generation spider clamp we introduced back in 2016, while it maintains excellent characteristics as far as stiffness and rigidity is concerned. No spider clamp from Aurora has ever failed and we firmly believe that this will be the case with our 790/890 spider clamp, hence this part is guaranteed for the life of your bike.
The all-new 790/890 Adventure rally tower was designed from the ground up. Based on our successful 701/690/9×0 series (no tower failures since 2016), this new design is a three-piece navigation tower. Splitting the tower into three separate parts has multiple advantages. First, the installation is a breeze. Second, if any parts need to be changed, it will be easier both from maintenance point of view (you buy what is needed) but this way, the service time is minimized as well. Third, the designers have the freedom to change thickness of the parts separately and this combination allows for perfect control on the stiffness of the assembly in a much more refined way. The ‘spine’ of the navigation tower needs to be stiff, but the front and the top part can be made more flexible, to protect the instruments and the light structure in the event of the crash. Basically, they will be the ‘crumple’ zones. So, before the spine is damaged, these will collapse to protect your gear. Combine that with the different materials used (aluminium, polymer, stainless steel) and you get the idea of the complexity of the design that was orchestrated so that you enjoy reliability and functionality at the same time in the simplest way possible!
The new design results in the main parts of the navigation tower to be 70% stiffer, while the new modular arrangement allows the main parts of the tower to be only a few grams heavier. The ‘spine’ structure, machined out of a solid block of aluminum, is seven millimeters thick, yet the special pockets allow the structure to be superlight. Keeping the tower very close to the weight of our 701 rally tower, the 790/890 Adventure structure benefits from the new ‘shorter’ design (i.e. the tower is closer to the bike), therefore the cantilever effect is further minimized as the center of gravity is now even closer to the bike.
Two attenuation dampeners (one on each side) further reduce the vibrations transmitted to the front structure of the tower.
The indicators are housed behind the screen, protected in case of a lay down, and the fins that the indicators are attached are removable so that you can attach them elsewhere if need be.
The cable management is unique and, in the package, a Tesa™ pet cloth wire harness tape is included, to make the installation as neat as possible. Special ‘gill’ inlets on the sides of the tower, allow the OEM harness to enter the unit with minimal effort and the front of the tower slides in a forward motion in order to be secured with ease while all the cables are attached.
The paint of the navigation is something that we are spending time too. The new, bright orange powder coat is a unique bright orange colour code and is in par with the new ‘orange’ language of KTM™. This kit is unique in all the ways!
The back plate of the 790/890 Adventure rally kit is a work of art on its own. The modular design allows you to remove the OEM instrument panel from the top position and by installing the extra handlebar back plate you can enjoy the view of two GPSs or mobile phones, whatever your adventure is! Laser cut out of a sheet of soft aluminium, this plate can house the OEM lighter power outlet and the KTM USB port from the 690 (should you want to install some more outlets apart from the included 2-port USB adapter). The vibration dampeners that secure the plate on the tower will protect the electronic equipment that you will install. The back plate design allows you to keep all 6 (!) adjustment positions of the handlebars without the need of moving anything out of the way.
Should you feel the need for speed and enter a navigation rally, we’ve got you covered! A special back plate can be installed, while the OEM dash is moved to the middle of the handlebars to provide valuable information, while the focus of the rider remains on the navigation gear.
Pioneering once again, Aurora Rally Equipment is the first company in the world to offer a CANbus controller for the lights of the bike. Since the bike has a smart electronic system, it automatically picks up that the OEM headlight is removed. This results in an error being displayed on the dash (HLU – Head Light Unit), which the rider has to confirm every time the bike is turned on. Aurora developed an electronic unit, which will work with the kit lights you will install to the bike and inform the ECU for the change. Hence an error free bike!
There are plenty of options in the Aurora 790/890 Rally kit. Road legal, or pure off-road, these lights will keep you safe during night travelling. The main beam is a Hella projector (60mm in diameter), with a high quality LED bulb. With a little bit more than 5000 lumens, these LED units will outperform a stock halogen every single time! For the high beam, there are three options to choose from. A 60mm LED unit from Hella, a street legal light that is taken straight from the KTM™ Dakar Rally winner, a Baja Designs Squadron Sport (off road use only) or a Baja Designs Squadron Pro (off road use only). The pro and the main beam will give you a combination of almost 10000 lumens to illuminate even the darkest places in your night ride.
The OEM rally mask and the stone guard from the KTM™ rally bike are used, and there is a special cover so that there is no reflection of light towards the rider from the screen when the lights are turned on. Increasing the safety of your night ride, as you are not distracted by the reflection of the light.
While Dakar winning bikes are changing, and that is because the race itself changes, we, travelers and adventurers all over the world, have somehow different needs. Protection from the elements and minimal buffeting are a paramount during our long journeys to our destination. The 2016 701 Xplorer kit was a pioneer in its own design and the 9×0 kits followed. We never place the screen in the same position in space relative to the bars as the KTM™ Rally bike. The reason is that each bike has its own aerodynamic envelope, rider position and the effect is chaotic. During our design phase, we always start by analyzing the riders position relative to some known database that we have. In this case our dataset was the 701 Xplorer kit which was very successful in this area (wind protection and minimal buffeting), but for the 790 we went a step further. A CFD analysis was conducted, and then we placed the screen on a prototype kit on our 790/890 Adventure, while we tested the bike back to back with the stock model. Four riders were involved for the test rides, to vary the height and the helmet type so that the dataset for the analysis was large enough to give us confidence on the results. The feedback from customers is already positive for buffeting and protection, something that screen only solutions and even the stock bike setup have failed to address.
The use of the KTM™ rally light support, stone guard and the aerodynamic side pods with the air ducts, all play an important role in the performance of the kit. Each part is optimized in its own way to operate as a part of the assembly, resulting in a flow which will allow you to reach your destination with minimal tiredness.
The windshield has special, spring loaded ¼ turn bolts with retaining washers so that you don’t loose the bolts, and the whole front of the bike can be removed without any tools. Made out of virtually indestructible PA6 (Nylon 6), this screen increases the safety of your upper body as it’s virtually impossible to break during off road riding. Not leaving sharp edges that can seriously injure a rider during crests the OEM safety is guaranteed.
The molded ABS side panels are the icing on the cake for the Aurora 790/890 Rally kit. Designed in collaboration with Dosmoto® and C-Racer®, the side panels are made from ABS. Both flexible and robust, they complete the front of the bike without interfering with the aesthetic language that the KTM™ 790/890 Adventure has. The stainless steel brackets are attached without changing anything on the bike, and they even come with special EVA foam and protective clear decals to protect the surface of the tank in case you lay down the bike and the side panels take the hit. The brackets are attached with Pro-Bolt® black aluminium bolts, while the assembly is completed by two quarter turn bolts on either side and the respective Dzus receptors. The whole front (windshield with the side panels) can be removed without any tools in a matter of seconds to give access to the cabling, should the rider is forced to do some roadside maintenance and repairs, clean the bike etc. Come painted matt black or glossy white. Should you want your custom colour, we can do it!
The weight is always an important factor. The 790/890 Adventure is the perfect way to explain to you that the actual weight of the parts does not actually matter. It’s the design behind them that matters the most. The 790/890 Adventure for example has a belly tank which keeps the fuel load low and the mass centralization on this bike is pretty unique. Just push the bike around and it feels feather-light. It’s not that it is light. It’s that the closer the mass is to the center of gravity, the less the ‘weight’ effect that we feel. The Aurora 790/890 Rally kit is designed with the same principle. The weight of the bike remains unchanged with the kit, but the center of gravity of the whole assembly is moved closer to the headstock of the bike, minimizing the ‘cantilever’ effect. The lights and the main parts of the tower bring the weight closer to the handlebars, while smart choice of materials, further allowed us to ‘move’ the center of gravity where we wanted it in the design phase. For example, the stainless steel bottom cover, is chosen (both in design, geometry and thickness) so that the center of gravity of the assembly is moved lower and closer to the bike. This results in a rally kit that not only will improve the looks of your 790/890 Adventure, but increase the functionality and performance as well!