By DNA Filters credits : https://www.drr022.com/ The Beauty of advanced kinematics! _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ …and this is how the idea of DRR-022 was born. The DNA Real Racer. The creation of a race-ready motorcycle with dimensions based on the Moto3 category of Moto GP equipped with an unconventional front system and manufactured only with materials and parts straight from the world championship. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Back in 2019, a new addition to the R&D team, Alexandros Maidis,a passionate engineer who is sharing the same passion about motorsports with Dino and Mario Nikolaidis, brought with him a portfolio provided with research on an alternative front system, based on the double wishbone suspension of Norman Hossack, optimized for lightweight motorcycles and a history of designing and manufacturing a couple of prototypes carrying a variation of such a set up. The last two years, owing to the pandemic’s lock down that has as a result the lack of business trips and exhibitions, lead the R&D team of DNA Filters, to thousands of hours of designing new products and innovative solutions for its production lines but most importantly gave them the opportunity to develop the new big thing… a lightweight race bike that will feature almost frictionless front and rear suspension! The target was clear. Near zero friction at all moving parts of the suspension, total weight less than a modern Moto3 bike but most importantly precisely engineered and manufactured. And the R&D team set the main features for this project: • Double wishbone front suspension • No use of ball joints, only preloaded double row ball bearings • Fully adjustable geometry • Special intake system using SLS & FDM 3D printing technology • Lightweight structure CNC Machined from billet aluminum • Moto3 spec parts & dimensions • As close as possible to 1:1 power to weight ratio • Carbon fiber subframe & fairings This project was set to be an extremely demanding engineering task putting human and machines to their limits with the highest quality and precision standards. As DNA filters always aims in all of its engineering fields. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Unconventional approach Already, modern telescopic forks feature good rigidity, acceptable static and dynamic friction. The target for the DRR-022 is almost zero static and dynamic friction. So it was clear from the beginning, the only way to go was by using nothing but ball and needle roller bearings in any joint for both front and rear suspension. No ball joints here! Another great aspect of this front suspension set up, is the fact that its kinematics are completely adjustable, meaning that the mechanic could change its characteristics in a couple of minutes, for instance, the percentage of diving during braking, just by inverting a couple of pivot points. Furthermore this front set up is designed in such a manner that provides a greater trail variation throughout the wheel travel aiming for the maximum stability during acceleration and high speeds without any compromise at changing direction. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Implementation The fork is attached to the frame via two asymmetric CNC machined wishbones made from 7075 T651 aluminum. The bottom one is responsible for actuating the front shock absorber via a pull rod, giving a travel ratio of 2:1. Double row, preloaded ball bearings, are used for every single joint of this setup. From steering to suspension movement, the friction is minimized everywhere. The steering input from the rider to the fork is transferred via a scissor link, that is also using preloaded ball bearings. The goal for this setup was to eliminate every bit of play, from the assembly and at the same time, maintaining rider’s input to the fork and vice versa, giving as much feedback as possible. A unique shock absorber is developed by Hyperpro for this application, fully adjustable in rebound and high/low speed compression. Additionally linear or progressive springs can be used. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Lightweight The chassis has a twin spar layout and is using the engine as a structural member. It consists of six CNC machined parts made out of 6082 T651 aluminum, welded together. With its 3mm wall thickness and its specially designed internal ribs achieves the preferable rigidity weighing only 3.6 kg. The rear subframe is made from carbon fiber. The front subframe is machined from 6082 T651 aluminum and apart from holding the steering assembly is also the top cover of the airbox. Despite the plethora of parts that constitute the front suspension, the R&D team managed to achieve a very low overall dry weight that does not exceed 75 kilos. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Breathing One of the key components of this project is the ram air intake. The induction of the engine is designed in such a way that channels the air to a specially designed panel filter, directly from DNA’s racing division. The intake system consists of two basic components: The intake and the airbox. Both of them are 3D printed and thus there were no constraints about the design and manufacturing process. The intake is 3D printed from Nylon-CF, manufactured inhouse and it also works as the upper fairing mount which means that it has a lot of structural rigidity. The airbox is also 3D printed made from PA12 Nylon powder, with Laser Sintering technology. One of its key features is the fact that it has specially designed channels to guide the throttle cables, that are traveling through it, without any opening that could allow debris to be “sucked” from the engine. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Acceleration A brand new Yamaha YZ450F engine was chosen to power “The Unconv3ntional”. It is a race proven engine with a power output close to a modern day Moto3. The engine is precisely tuned in order to improve top end power output without compromising on reliability. A stand alone ECU took the place of the OEM one, in order to match the needs of the DNA forced intake system and the Akrapovic exhaust that is bespoke built for this bike. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Deceleration The braking system of this lightweight racer is directly derived from the latest Moto3 bikes. Calipers and master cylinders came from Accossato racing series. The front brake assembly uses a twin rotor layout with rotors of 220 mm in diameter -manufactured inhouse- and two twin piston radial CNC machined calipers. The radial master cylinder in the front is adjustable to 17/18/19mm of leverage.The rear radial caliper, like the front, is CNC machined twin piston and the rotor is 200mm in diameter. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Telemetry In a project like this monitoring everything is mandatory. Especially during the development. Thanks to the wiring loom custom-made by our partner Plex Tuning, every key aspect of this motorcycle will be monitored. Suspension position, steering position, accelerometers, GPS and brake pressure are few of the inputs going to the telemetry, plus full engine data. Everything is logged and displayed in the SDM-330 dashboard. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DRR-022 Specifications Engine: Single Cylinder Racing Engine Capacity: 449.7 CC Engine Type: Water Cooled Bore/Stroke: 97mm/60.8mm Compression Ratio: 13.0:1 Valve Train: 4 Overhead titanium valves Fuelling System: EFI,Keihin 47mm Throttle Body Transmission: 6 speed Clutch: Wet multi-plate clutch Final Drive: Chain Frame Type: Twin spar,Aluminum CNC machined Sub-Frame: Carbon Fiber Wheelbase: 1280 +/- 10mm Fuel Tank: Aluminum Fuel Capacity: 11.8L Weight: 75kg dry weight Air Induction: 3D printed FDM NYLON-CF Ram-air & 3D printed SLS PA12 air box with DNA racing filter Exhaust: Akrapovic full titanium custom made for the DRR-022 Front Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022 Rear Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022 Front Master Cylinder: Accossato Moto3 racing Rear Master Cylinder: Accossato Moto3 racing Front Brakes: 2 x 220mm disks, 2 piston Accossato Moto3 Radial billet calipers Rear Brake: 1 x 200mm disk, 2 piston Accossato Moto3 Radial billet calliper Considering all the things above we believe that the end result is nothing short of amazing. Today, here in Milano, at Eicma 2022, we proudly present to you one of the most challenging projects that we have put our hands on, showing on a global level, what our company is capable of. Firstly, Dino Nikolaidis, co-founder of DNA Filters, using his racing experience, engineering and machining skills and his knowledge around materials like aluminium, titanium and stainless steel contributed decisively to fine tune the project setting the standards in some of the most critical parts and the overall manufacturing quality. Next, Mario Nikolaidis, managing director of DNA Filters, through his valuable experience in managing and his modern communicative point of view, is the person who divided the duties and set the deadlines, coordinating the team, aiming to the best results. Besides, the right orchestration of a team for a project like this is equally important with the project itself. Alexandros Maidis, the man behind this project, was responsible for intriguing the team with his vision in a first place, remained open for new ideas, suggestions and advices concerning his design. Always there, contributing to anything he was asked and ready to advice and consult, kept the level high. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Conclusion The team behind this operation is the whole company of DNA Filters. From the major contributors of R&D team to the procurement department. From the marketing division to the production line one thing is for sure, that without them, the end result wouldn’t be one that lives up to DNA’s standards. Design & Engineering excellence! We hope that you will enjoy The Unconv3ntional. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Gallery
Our best seller fairing kits for KTM 690 Enduro 2008 2018 are nearly 7 years on the market ,with great feedback and the most important no failures!! During the years we have update these kits from scratch and we made them even better . Why choosing this kit ? Let us explain why in few lines .. -First of all we use OEM KTM windshield - headlight cover and also the clear protection for the headlights ,these parts was designed for the KTM 450 Rally bike (yes the one which participate on the Dakar race) so there are no better thing than a great OEM product ! -The lights are MOTORCYCLE street legal lights ,made by Hella a top brand company . Also the position light are OEM Hella not a simple noname light .. -Headlights wiring harness are made from SmartMoto , a company which is well known and one of the top brands for electronics in EU . -Side panels are made with the best materials to last long . Not just MATT glassfiber and polyester but woven roving fiberglass and ecological resins . -Navigation tower is made also from a motorcycle spare parts company and not on a small workshop . With top quality materials and hard tested ! We can write many many things more but these are the most importand ,you are not buying a kit which is made from a single person but parts which are designed from serious companies with many many years in the fields ... DOWNLOAD THE MANUAL HERE: 2008-2018 ktm 690 enduro 2008 2018 GEN1 GEN2 Installation Guide 2019-2020 ktm 690 enduro 2019 UP Rally Adv fairing kit Installation Guide
Dario Pena ,AKA Riding.The.World.DP , its a passionate rider based on Mexico. Dario was one of our very first customers on the KTM 690 Enduro lite fairing kit and the very first one which received the Mastech navi tower! Now after many many rallies which he participated and a lot of Km on adventure riding is the suitable rider to get an accurate feedback after his last 15000Km adventure "Continental 2019" : You can watch a documentary video of his bike build : https://www.youtube.com/watch?v=Lom1Y3uqr8M&t=34s Also dont forget to subscribe on Riding The world DP youtube channel and watch more videos !! https://www.youtube.com/channel/UCQ9VZerijwHlJTp8VFLKNGw
A great build from Austria by Tom.
It was time to start working on the new KTM 690 Enduro,so we start from drawing new designs and ideas about this new kit . The main idea which finally done reality was to keep the standard lines of the bike and make the kit as factory can be ,no new design from scratch but with the same lines . We decide to keep the OEM KTM Windshield from the previous model as we love the design ,its hard hard tested from KTM all these years on the Dakar rallies and all the FIM rallies arround the world .Also it comes with the OEM KTM Stone guard to protect your lights and the OEM KTM headlight mask ! The lights also remain the same Hella street legal lights but with the option if anyone need to update them to Hella LED street legal lights (withg additional cost) ,and also we use the OEM Hella LED position light . Lights comes with a plug and play wiring harness made from top quality materials and following ISO roules ,made from Smart Moto electronics a top brand with high quality standards! Navigation tower is also the same as on the previous models ,made from Mastech . Made from aluminium ,hard tested as we use it now for over 3 years withoout any fault ! With plenty space inside to fix your cables and have access to anything during a trip ,also the cables are inside the tower which provides an extra protection . The main headstock bracket was updated and comes ready and really plug and play ,with a CNC machined bracket and the safety which provide the M10 U-Bolt we use this bracket made to last forever.It mounts easy without removing the ignition key and without relocate the expansion tank. Side panels ... The new side panels are made to make your bike looks that is a factory KTM rally bike and not a kit which installed on your bike .Comes ready to install ,just remove the black side front panels and install your new ones ! Toolbox will be there for your tools as on the OEM panels .Very strong and durable and same time not heavy ! This kit made with love for anyone which like to have a factory adventure bike and not just a kit on his bike ..
Last year a customer contact us and asked for a rally adv kit for his next bike , he had to move from his country to UAE according to his job and he was in need for a new bike to cover his needs on the desert and long distances without gas stations. We was between the KTM 690 E and the Husky 701 E .The problem was that we didnt had a kit or anything for the 701 .. He said as he was a 690 owner he would like to have a 701 and he asked if we could buy a 701 and convert it to a Adventure bike with auxiliary fuel tanks ,navigation tower ,a bullet proof engine protector and anything else was needed to make the best Adventure bike out there !! We said: -YES ,lets do it ! We didnt loose time ,next day we contact the dealer in Greece and we bought the bike . A low used bike (approx 2000Km) in perfect condition this was the best option for our adventure build !! The project was to make an adventure kit which will be extremely simple to mount on the bike ,we choose to use the KTM 450 2015-2018 Windshield and some other parts from this model for our project . KTM 450 RFR 2015-2018 Windshield is a windshield which has beed tested under extremely terrains and rallies arround the world and of course on the mother of rallies the Dakar rally . First task was the fuel tanks ,we removed the plastic panels of the bike and nothing more .We didnt relocate anything as our project was a kit "friendly" with all the meaning of the word .As we had made a kit for the KTM 690 E now we was wiser and we had a big experience how to do a better one . We start modifing the KTM 690 E fuel tanks in order to fit on the 701 frame as is ,with all the parts of the frame on its original places .It was not an easy job ,we failed many times to make a proper fit fuel tanks . After all these fails we finally did it !!The fuel tanks had a great fit with the frame of the bike to be as is with no mods and relocations like " relocate the regulator " - " relocate the horn " - " cut the plastics " - " remove the airbox " etc . Standard exhaust remain on its original place ,no extra lower pipes needed . The seat fits on the standard brackets and on the frame not on the tanks or any other extra bracket . Fuel tanks can hold 13L on total ,comes with a Dakar tested KEIHIN fuel pump .The fuel tanks conection its really simple ,just link the rear tank on the front tanks and work with the Keihin pump or you can make it work with 2 fuel pumps and keep control of the fuel as you will have the option to choose which tanks will empty first ! -Tanks are made of multy layers Carbon Fiber ,epoxy resins and reinforced inside with vinylester .Vinylester is one of the best materials to protect the tanks of the acid fluids . -The brackets we made are billet aluminium made on a latest technology CNC machine. On the Husky 701 you will find 4 mounting points on the front main headstock ,these points.These points was the perfect place to fit a proper and biller bracket for the navi tower ! -Navigation tower we have made 2 options : 1.Mastech Navi tower This is the best navi tower out there ,extremely simple and compaq .With a lot of space inside to fit all the wiring harness proper and clean . It comes with a plate for all the standard indicators ,Δ button ,the standard speedo and lot of place to add your own GPS or your tablem .Optionaly can come with a Roadbook plate with OEM speedo place-indicators and 2 icos . It comes ready with all the bolts and spacers for Hella lights- KTM mask . Weight of the tower is 2.3Kg 2.PF Carbon fiber tower This option is great solution for anyone which asking a low weight tower ,it have all the benefits of the Mastech's tower .Its taller and in some cases require to extend your standard wiring harness .It comes with a plate for OEM Speedo-indicators and GPS and optionaly with a KTM OEM Rally Roadbook plate . Weight 910gr -For lights we use Hella lights ,as these lights are great for riding and are street legal all over the world! Hella is a top brand name on lighting solution and is used on many many auto moto companies and of course on KTM Dakar bikes ! -Skid plate (engine guard) ,this is a crucial part so we had to make something wich will keep strong on a big rock or even a crash but not so heavy.The best material for these job is the Carbon Fiber with aramid (Kevlar) reinforcement .A multi layers Carbon Fiber is the best way to protect the expensive engine of the bike and the fuel tanks with the also expensive Keihin fuel pump! -Side panels which hold the OEM KTM windshield and connect it with the fuel tanks are made of fiberglass .extremely strong and easy to mount .Made to mount on the Husky like the standard side panels ! -Seat ,we had to modify the seat in order to fit with the new tanks in front .New seat comes with Carbon Kevlar seat pan - comfortable foam and rally style cover with a pocket in the front .It fits like the OEM seat. On this build the main colors which Alejo (customer) asked was the black .. so we asked from our grafix designer to make the decals based on black color .The design he made was amazing and you can confirmed it on the pictures ! The last pieces of this great build was the rear side panels-the rear and front fender and the handguards ..We had to make something to be nice with the black theme .. What better of the black color from Carbon Fiber . In fact we build a complete Carbon fiber kit as all the parts of this bike are Carbon Fiber !! The bike was finally ready ,last task was the paper work and the flight to UAE from Greece but with some good faith everything solved and now Alejo enjoying his bike at the UAE deserts !! His feedback after a year of hard riding : "The kit.... I will recommend to everyone without doubt. It fits perfect on the bike, easy to install and easy to take it off for maintenance. Navi tower is also easy to work with, a lot of space for cables and everything there. Lights are good, definitely the kit is strong, I have had several falls some of them on hard rocks and some others on soft sand but fast and nothing but scratches."