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Old 09-30-2007, 11:50 AM   #1
hondahawkrider OP
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Joined: Mar 2005
Location: Laurel, MD
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Winter Project - 1998 KTM 620 EGS-E Adventure to ADV/SM

I just bought it from a a friend of a friend - he and I have been on a motorcycle listserv for years - and is a friend to my friends... He is the original owner - it's got less than 6k miles and runs strong - the major detractor is that it spent all of it's life outside so comsmetically - it's rough.... Which for my purposes is great because to suit my needs I was going to mod it -rhino liner the plastic parts, SM wheels -etc, and well the price was right....

The funny thing is that it's supposedly 1 of 50-60 low pipe KTM EGS-E Adventures ever brought into the US... I was going to bend em up ala a dakar style - but we shall se.. Anyone know how many EGS-E low pipe models were brought in to the US






It looks like my SXC dirt wheels will fit - so hopefully I can use the orignal hubs and lace to em to some wider rims.... The 1st step will be to clean up the rusty bits and to scrub the tank - and see bout painting the faded body parts (I am thinking - rhino liner )

Here goes nothing..
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hondahawkrider screwed with this post 09-30-2007 at 11:58 AM
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Old 09-30-2007, 11:55 AM   #2
JAFO
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I believe Durabak has a smooth liner material that is a close match for Katoom Orange....
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Old 10-01-2007, 06:05 PM   #3
hondahawkrider OP
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Started work on the bike - pulled the bags

and here is the dash with rusty mirror (only one)

As MD requires two mirrors - I checked my part bin and I had tons of hand guard bolts and a pair of faux carbon fiber hand guards and DRz400sm/Vstrom mirrors - all of which are now on the bike

I will probably pull the bars in the future to clean it up more - but the 1st step is get it inspected and on the road.... So I can ride it to the deal/friends places to get some misc work done
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Old 10-22-2007, 07:57 PM   #4
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it's nekkid

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Old 10-23-2007, 09:23 AM   #5
Foot dragger
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Dual low pipes, that looks pretty trick. I was thinking of getting some kind of low pipe with a skidplate on it for a 98 SC620 I had. The stock pipe runs right next to the radiator,the carbuerator, the air box,and around the shock heating all these parts quite a bit. I ended up wrapping the pipe which was the cheap thing to do.
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Old 10-23-2007, 11:47 AM   #6
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There are some closeup pics at http://s137.photobucket.com/albums/q...KTM%20Project/

The plan now is as follows

The 1st thing to do is to get the surface rust off the frame and make some improvments. Rad fan switch is missing - it stopped working and the PO wired out a switch that isn't mounted anywhere so I am going to mount it on the dash, as well as a choke. The bike has a FCR carb on it, but it's an older one with no choke (If its really cold - you pop the seat and cover the up the intake and it will start - but it's a pain). I want to see about popping the cover and running a choke cable up to the dash like the fan switch. I should be able to use a older car cable and put a knob on the dash - won't be OEM, but will work...

The plastic is off to be painted too, it will be a rattlecan paint job (I priced out a professional job and it's WAYY too much $$ for my cheap ass). It's gonna be my offroad bike - so Krylon Fusion will be good enough (it's gonna be all black), buddy nicknamed it Darth KTM... LOL..

The clutch is a little sluggish - so I will do new plates and springs to see how it does, it works but it's as responsive as my SXC...

The exhaust is going to be the big ?? Mine has some minor rust spots - so they will be coming off and being cleaned up (see the shots of the rust where the headers mount)... My issue is that I like water crossings and the low pipes are less than ideal... I have thought of getting some other type slipon and putting it on the bike. Similiar to this
It would be cool to do this on both sides like the rallye versions, but there are some issues that concern me - it would require using the OEM connector running underneath the bike; the current skid pad doesnt cover it so I would have to get/make a bigger longer one, and it's the main reason I can't put a center stand on it (came off my SXC - as a SM it doesn't need it). I really want to do the two pipes on each side - but its far easier to do the one for now. Using the OEM header I should be able to use the OEM Skidplate - (Not shown on the attachment) and the centerstand will mount up and will hopefully help protect the single pipe running along the bottom side of the bike

Per the orig owner of the KTM 620 with the Supertrapp - he has this to say

that single exhaust using a Supertrapp Kit for a YZ 450F. All that was needed were a few hose clamps and a connector for the stock 2 into one head pipes. I also fabricated a bracket for the muffler

Lastly, if anyone knows of a set of the rally tanks that fit on the rear that don't require a home equity loan, I would be interested - buddy and I would think it would look cool to make this look like a rally replica - let face it they look cool all dirty and used (and this will never be a concours style bike).. The 620Adv has a beefier subframe and could handle it without playing switchies with the subframes - see my comparison pic -
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Old 01-21-2013, 11:33 AM   #7
biensur22
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I'm about I put an FCR on my own 620adv. What did you do for the choke? Can you use the stock cable/fitting? Any chance of a pic?
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Old 01-21-2013, 12:46 PM   #8
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Quote:
Originally Posted by biensur22 View Post
I'm about I put an FCR on my own 620adv. What did you do for the choke? Can you use the stock cable/fitting? Any chance of a pic?
I'll take a pic when I get back to it... It's not in my garage... I didn't mount it. However, I did put a fcr41 on my sxc (03 with bst40) and it went fine. There was a nub I had to grind down a bit, but it worked great... I can't say if one for quicksilver carb is the same or not...
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Old 01-30-2013, 07:15 PM   #9
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Crashbars and speedo ordered



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Old 01-30-2013, 07:36 PM   #10
Low594
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Quote:
Originally Posted by hondahawkrider View Post
Crashbars and speedo ordered

Sorry to be the bearer of bad news! Unless Holan added the older versions (pre '03) recently, these will not fit! I got a set a couple years ago and was really disappointed!

For clarification, the motor mount plates for the front of the frame are different and so is the nav tower bracing.
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Old 01-30-2013, 08:01 PM   #11
hondahawkrider OP
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Quote:
Originally Posted by Low594 View Post
Sorry to be the bearer of bad news! Unless Holan added the older versions (pre '03) recently, these will not fit! I got a set a couple years ago and was really disappointed!

For clarification, the motor mount plates for the front of the frame are different and so is the nav tower bracing.
Didn't expect em too.. I will get something fabricated, but its way easier to start with a template and work from there.. It was something to work on after I get it running and on the road, but its getting harder and harder to find any..
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Old 03-03-2013, 01:47 PM   #12
hondahawkrider OP
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Quote:
Originally Posted by Low594 View Post
Sorry to be the bearer of bad news! Unless Holan added the older versions (pre '03) recently, these will not fit! I got a set a couple years ago and was really disappointed!

For clarification, the motor mount plates for the front of the frame are different and so is the nav tower bracing.
Ok, as stated bars don't line up. Shouldn't be to hard to fab something. However, what I'm going to need t start, is a beefy skidplate to serve as a bottom mounting spot.

Anyone know of a beefier skidplate than the OEM.
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Old 01-30-2013, 08:07 PM   #13
biensur22
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Quote:
Originally Posted by hondahawkrider View Post
Crashbars and speedo ordered



That speedo looks awesome. Are you gonna try to use the fuel gauge? What's the price? I need to know my options for when my stock tripmaster finally gives out.
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Old 03-02-2013, 12:35 PM   #14
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Inspected and tagged... Time for paint





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Old 03-02-2013, 02:52 PM   #15
Low594
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Congrats!
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