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Category: Protections

Protecting your bike from the vagaries of driving. On and off road.

Rear footpegs sliders

To protect the rear, the footpeg sliders from the 790 Duke fits just fine, and provide a sacrificial bit of nylon instead of the expensive aluminium piece. Get yourself some piece of mind for cheap (P/N 61303946044, $13). Thanks Orfeas for the find!

Alternatively, if you have access to a 3D printer, advrider inmate Marchyman made a model to do the same part.

ABS sensor/cable protection

The rear ABS sensor, and more importantly its cable, are not well protected. A misplaced branch can snag on the cable.

Motominded makes a cover protecting the cable and the sensor. $20.

Another less protective option, that protects the sensor but not snagging of the wire, is available from a fellow on the French KTMmania forums for 3D printing (registration required, French mandatory to understand anything). STL file is send on request…

Hand guard

The standard handguard (black on the S, black and orange on the R) are good but are not perfect:

  • They are all plastic and can deform on impact, not completely protecting the levers
  • They prevent rotating the levers down as they don’t go far enough on the handlebar. If you spend your days standing up this count.
  • Depending on their position the various cables are ragging against them.

Third party hand guards have better protection, and attachment points leaving more space to the various cables.

Warning: Space is limited if the handlebar is moved to its most forward attachment points, it may cause the hand guard to touch the TFT at full lock; Same punition if the handlebar are tilted forward while in the center position. See this extract from the fitting manual for the Barkbuster, but this applies to all models (especially the KTM metal one, which is a Barkbuster in disguise!):

Barkbuster install highlight

Here is a non-exhaustive list of robust hand guards with a two point metallic wraparound. Of course there are other options, leave a comment if they are worth mentioning here. See also this thread on advrider for more options.


You need to order three parts:

  • First the Hardware Kit, get the tapered two point mount reference BHG-152. It’s a big aluminium bar solidly bolted.
  • Then a plastic part to screw on it. Lots of choice there as most of the barkbuster hand guards mount on this. The VPS ones are a nice fit, in plenty of color choices, including orange (reference VPS-003-OR)
  • A 10mm spacer and assorted bold B-078 for the right side otherwise it may interfere with the brake lever.


The X-Factory is cheaper than the Barkbuster for a similar protection. This is also available in plenty of orange versions (black/orange, orange/black, white/orange and orange/white). The metallic bar is steel, very very robust. The Acerbis also require an additional 10mm spacer between the handlebar mount and the bar on the right side for a perfect fit (10mm might be too long, there is a report that filling it down a bit prevents it from hitting the TFT display at full lock, see the warning at the beginning of this article). Example of install.


HDB makes an interesting model that uses the bar clamp as support location instead of the handlebar. Some pics in this article. Another install reports that those ultimate handguard bolt nicely in place but do hit the TFT. There is a detailed install report on this advrider post.


KTM also offers a handguard with a aluminium insert, that mounts on the 790, p/n 63502979000EB. Turns out this is an OEM Barkbuster frame with different plastic on it. See those two install report.

Fuel tank protection

The standard plastic covers are quite cheap to repair if scratched (about £35 each?). They seem to sustain impact abuse pretty well, but in case of slide on tarmac probably offers very little in term of abrasion resistance.

It’s also a good idea to inspect those protections from time to time for trapped gravel, as those may scratch the tank on a fall.

KTM offers a carbon fiber replacement in the catalog (p/n 63503990044, about £306) which is default equipment in the R Rally.

carbon fuel tank protection

In the UK Kodama composite is offering a carbon/kevlar cover to put on top of the existing plastic protection, adding the abrasion resistance (Kevlar is very resistant to abrasion, carbon by itself is not). £110. (source)

Rade/Garage makes swanky replacements for the tank protectors in carbon/kevlar. €279.

Crap flap

There is a big hole right behind the front wheel where mud and stone love to collect. There are report of riders in dry places having grass accumulating there and catching fire against the headers.

The prototype bikes and demo bikes in Morrocco were all equipped with a piece of metal to cover it.

Note that some replacement skid plates are going to cover this space, if you plan to add crash bars or third party skid plate check that you can still install those covers.

There is one on listed on the powerparts catalog (p/n 63503991044, €70, and note that the picture in the catalog is not exactly like the real thing) and third party jumped in to fill the gap.

KTM crap flap (Photo Anders F. Eriksson)

One can make their own filler with a piece of mesh from any source, as this example.

Sweetlamb KTM Adventure Bike Experience <> developed a model for their bike in 3mm black HDPE, and are selling the result on ebay for £35, plus £2 shipping.

Sweetlamb KTM Adventure Bike Experience HDPE crap flap

There is another model, aluminium, branded by the company terratech, also available on ebay for $56 + $10 shipping for US/EU. Includes pop rivets as mounting kit.

Terratek crap flap

An outfit call vit garage published a KTM branded one on Facebook. Contact to order. €60 + shipping from Portugal, includes mounting kit.

Ready to race crap flap

And another one from coober, €59. Includes pop rivet as mounting kit.

Coober crap flap

And Bumot too, from Bulgaria (no price yet)

Bumot crap flap – Pic from niksami on advrider

Another one from Braaap! on adv rider. Lasercut 2mm aluminium. Including mount hardware and postage, $50 for the mill finish, $65 for a satin black finish. Contact via DM on advrider for more details or ordering.

Braaap! flap in mill finish.

The most recent entry, if you like the Venetian blind look is this thing from twalcom, available in various colors including “racing orange” (note also the black bash plate of unknown origin).

Twalcom flap in lurid racing orange.

Bottom protections

There are multiple type of protections available for the bottom and side of your 790 Adventure. The original setup is a relatively thin aluminium bash plate, with two plastic ears to protect the bottom of the fuel tank.

There are tons of options to upgrade the protection, especially for off-road.

  • First you can add a piece of metal or plastic to close the big gap under the radiator. This helps prevent projections from the front wheel to land in the bash plate. These have been nicknamed “crapflap” and there is a whole page dedicated to them.
  • You can upgrade or supplement the plastic protections for the tank lobes. The original parts are sacrificial, cost €35 to replace, and do protect well on impact; But a slide on the tarmac will get through them. There is also another full page dedicated to them.
  • You can replace or reinforce the original bash plate. There are numerous offering that are a direct replacement of the original in aluminium or carbon. Some do cover the crapflap hole, some don’t. Some mount on the original mounting points on the engine, some avoid them using a bracket to use the center stand mounts instead. You will find them all below.
  • Then you have the complete bottom cases, replacing both the bash plate and the plastic sides with one big piece of metal or plastic. Those are further down this page.
  • And finally, you have classic crash bars.

Bash Plates

Those only replace the original bash plate, and most also stop using the engine as a mounting point in the rear. Note that makes them incompatible with center stands.

Chappel plate

An inmate at advrider, Ian Chappel, is doing a batch of very nice replacement bash plates, attaching to the center stand mounts. No web site, but a PDF doc with all the info. £200 (plus VAT for Europe), shipping extra. See also a report of a satisfied user. Also covers the crap flap zone.

This bash plate is now fabricated in NewZealand under licence, only for NZ market, to minimize freight cost. 500 NZD.

Chappel custom bash plate

AS3 Performance plate

AS3 Performance list a 4mm aluminium bash plate on their web site (£180). Attaches to the same points as the original part. Note that it doesn’t covers the crap flap area. Watch this detailed install video about it.

AS3 bash plate

BDCW Plate

Black Dog Cycle Works is building a solid replacement aluminium part in a range of finishes. $350. Covers everything, doesn’t attach to the engine but to the centerstand mounts.

Rade/Garage carbon plate

Rade/Garage went another way with a bottom plate in carbon/kevlar. Can attach to the same anchor points as the original plate or to a support (included) that connect to the pegs. Or both. Slick, and competitive on price for a carbon part: €370.

Rade/Garage carbon/kevlar plate

Enduro engineering

Not a lot of details there, but Enduro Engineering, in the US, has a bash plate on its web site. Includes the crap flap, and it bolts to a solid mount point in the rear. $220.

Enduro engineering skid plate

B&B Offroad plate

B&B off-road also has a bash plate, that can be paired with crash bars. AU$345 without, AU$935 with. Apparently not using the engine attachement point, but still compatible with center stand. Waiting to see the design.

AltRider skid plate

Another solid replacement bash plate, replaces the original and avoid mounting on the engine in the rear as well as covering the crap flap area.

Touratech reinforcement plate

Touratech takes a slightly different route and offers a reinforcement piece for the skidplate (Item # 372-5158). You install it against the back of the skidplate, so you won’t be able to see it when it’s on. This add a bit of robustness to the original plate.

Touratech Skid plate reinforcement

Bottom Cases

Those do replace the original bash plate and have ears to protect the tank as well. Those are incompatible with all other underside protections and likely to make the installation of a center stand impossible.

AXP Racing spend a few months developing a bottom plate. It protects the bottom and replaces the side protections, and it is all plastic, AXP Racing specialty. Mounts to the original mounting points in the front and to a pair of aluminium brackets in the back bolted to the chassis. AXP Racing doesn’t sell directly, but through distributors, price may vary. Rotweiler Performance list it at $277.

SW_Motech makes a giant protection covering the whole bike bottom. All aluminium, 4mm thick. Looks robust, but bolts on the engine.

SW-Moteck bottom case.

Bumot has one. €275. aluminium.

ACD is also offering a big case covering all the bike’s bottom. Available for €230 or £205 in the European store, but not listed yet on the US store.

Crash bars

The consensus seems to be that crash bars are unnecessary on this bike. The fuel tank protection are all the protection you need, they are intended to be a fuse and replaced once dinged. But this will not stop third party to make some, and some people installing them. But do check where the crash bars are anchoring to.

SW-Motech have low bars available. See this review.

Outback Motortek are making crash bars, high and low, with optional bottom plate. See the video.

Touratech made a video with a lot of stuff visible on the bike (crashbars everywhere, luggage galore, headlight protection, hand guards). These are slowly starting to appear in their catalog (crash bars are €240 in your choice of color: metal/black/orange).

Hepto-Becker has crash bar in black, orange or metallic finish (Those have been reported to have to be removed for an oil change as they are in the way).

Metal mule released crash bars that protect the tank lobes. £140.

There will be more.