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Old 03-08-2011, 04:29 PM   #1
kiwipeet OP
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Location: Gizboooooring
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Project bike: 2007 KTM LC4 640 Adventure

I've started this thread to share my project of restoring a mates damaged 640 Adventure.

Here's how she looked when Mike first got it.



I intend to restore the bike so she looks just as good again.

Mike bought the bike 2nd hand in the UK, and was riding from London to Capetown. If you want to know the background of where the bike came from, and how it came to me, you can read about it here.

kiwipeet screwed with this post 05-12-2011 at 08:53 PM
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Old 03-08-2011, 04:30 PM   #2
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Day 1: Picking it up in Auckland

Monday 7th March 2011.

This day has been a long time coming. Today is 10 months to the day since Mike's accident.

Jess and I took the wagon up to Auckland to pick up the bike. We didn't know what to expect or what we would find. After handing over the paperwork we were sent into the yard and told to wait while they brought the crate out. As soon as we see it we notice it has been re-crated.



Looking through a gap in the side it appears the bike has fallen over but it hasn't. Whoever built the crate did a pretty good job and the bike is still upright, and apparently no worse than when it Left Gabon.


The left hand side of the crate had been opened by MAF... the board was loose so we decided to take it off completely rather than lose it on the motorway.

And there she was...





Jess and I took a few minutes to take it in, before securing the crate and hitting the road. We had an 8 hour drive to get home.

Once we arrived home it was getting dark, and we just wanted to get the bike off the trailer and into the shed. The only way to do it was dismantle the crate on the trailer and wheel the bike off.

kiwipeet screwed with this post 03-29-2011 at 03:55 AM
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Old 03-08-2011, 04:30 PM   #3
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Day 2: Assessment.

Tuesday was a long day at work... I just wanted to be at home in the shed. Jess and I started by cleaning up the shed and started to gingerly remove bits and pieces, and try and get a feel for the extent of the damage. The photo that sums it up the best is here.

The tank and fairing are obviously damaged, which in turn has crushed the left hand side radiator and all the related front end subframes..

I keep looking at the the oil I see dripping off the engine and out of the bashplate. I'm worried abut what I'm going to find underneath. A cracked engine case or sump? fingies x'd...



As we remove the front fairing we find a yellow bottle completely squashed flat between the fairing and the tank where they're crushed and oil everywhere.. it's the first of many surprises Im sure Mike has left for me.. it turns out it's the oil bottle for the Scott-oiler Mike fitted to lube the chain. Somehow he mounted it inside the fairing, and it got crushed in the accident. Hopefully it's the sole cause of the oil dripping off the engine.

At the end of the first day we've got the outer layers off and can see that generally she's not too bad. The main chassis appears straight, the forks, wheels and engine appear intact and serviceable. To say that I'm relieved is an understatement.

kiwipeet screwed with this post 03-09-2011 at 02:42 AM
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Old 03-09-2011, 12:28 AM   #4
Brendan J
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Hurry up haven't got all day!!!! I have a new bike that I'm dreaming of picking up before the end of the week.
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Old 03-09-2011, 01:39 AM   #5
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Day 3

Back the shed again tonight. I took a few more photo's and started on the next layer. This is basically where I left it last night.



Generally I'm pretty happy with what i'm finding, and keep picking at the next layer still trying to find the limits of the damage.

The Left hand side radiator is crushed, and takes me an hour of fidgeting and prying to get off including some not so subtle use of a
crowbar.



I can see a few of the radiator hoses are creased and split too. the radiator fan is crushed and cracked just enough to be knackered. I'm chuffed to find the right hand side radiator is unmarked.

I took the bash plate off and had look underneath, there's still a lot of oil, so I still don't know if it's leaking. There's no obvious cracks. I gave it wipe underneath, and i'll check it again tomorrow.



I'm surprised the bike passed MAF inspection, it's covered in mud and grime... So i've decided to get it water blasted before I go any further.

kiwipeet screwed with this post 03-09-2011 at 02:46 AM
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Old 03-09-2011, 12:13 PM   #6
clintnz
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One of the US 640 regulars posted up in thumpers recently with some pics of some aftermarket high capacity radiators they had just got for a good price, might be worth looking into if that bent one isn't fixable. I'll have a poke around & try & find the thread.

Edit, found it, ASI rads & hoses: http://www.advrider.com/forums/showp...7&postcount=38

They sell ASI stuff in NZ I think, so ask around locally. It might end up cheaper to import though.

Cheers
Clint
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clintnz screwed with this post 03-09-2011 at 12:30 PM
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Old 03-30-2011, 07:55 PM   #7
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"Shed defrag"

I'm hoping to have a few busy days working on the bike this weekend. In fine family tradition flat surfaces attract things. Work benches are shitmagnets, that things get stacked on. As a result my huge work bench is unuseable because it's chock full of crap.

I have a work bench at one end, with tools and a vice and power.. and I was working at the other end in a corner. So i'm constantly walking back and forth to find tools etc.. and constantly stepping over and around things like our other bikes, saw horses, contaiers, mowers etc.

Solution: move the work to the bench, and move stuff thats not being worked on away. It seems so obvious now, but I thought I was a rocket surgeon for figuring that out.

So I decided to have a bit of muck out and "defrag the free space" on my shed floor. Lots of sorting, stacking biffing, and sweeping... I filled a 20 litre can with shite off the floor.. where did that come from?



So now I have a clean workbench, I can find my tools, reach the power socket, and have enough room to swing a cat (not overhand).

Oh yeah and my filter kit arrived in the mail today. So I hope to shout her an oil change and something like a service once we get her running.

kiwipeet screwed with this post 03-30-2011 at 08:32 PM
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Old 03-30-2011, 09:15 PM   #8
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I filled a 20 litre can with shite off the floor.. where did that come from?

Yeah, where did you get the 20L can from?
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Old 03-31-2011, 12:22 PM   #9
clintnz
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[QUOTE=kiwipeet;15549133]
So I decided to have a bit of muck out and "defrag the free space" on my shed floor. Lots of sorting, stacking biffing, and sweeping...QUOTE]

Nice! I do like a tidy workshop.

The weather looks ok for the weekend so I'm planning to bring the bike over, that will give us a source of known good parts to swap in if there are any tricky problems to diagnose. I'm not sure it will be allowed in that shed however as it's still filthy from last weekend Any tools required apart from the basics?

Cheers
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Old 03-31-2011, 08:20 PM   #10
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Originally Posted by clintnz
The weather looks ok for the weekend so I'm planning to bring the bike over, that will give us a source of known good parts to swap in if there are any tricky problems to diagnose.
Sweeeeeet... you can always catch a bus home if we can't get yours back together.

Quote:
Originally Posted by clintnz
Any tools required apart from the basics?
Umm not that I can think of.. I have a resonable selection of basic tools and can borrow odd stuff. If we really need summink Supercheap, Repco or Bunnings are only 5 min away.

Eer... I can't find my multimeter anywhere, so If you have one handy I'd appreciate if you could bring that over just in case we try chasing leccy gremlins.

See you 2moro
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Old 04-02-2011, 02:58 AM   #11
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Thumb Keep up the good work

Proud of you lill bro, keep up the good work.
Help yourself to the tool cupboard.
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Old 04-03-2011, 01:33 AM   #12
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whoa what a weekend.

Well I can honestly say I've had a bloody fantastic weekend

We got a whole heap of work done on the bike and made more progress than I dared to hope.

The plan for the weekend: Get the bike started.

It started on Saturday morning, I ducked to Repco and got some more oil, expecting we'd be topping up the bike to get it started, and all going well giving it an oil change. I got home and watched the rain, waiting for Clint to arrive... when a courier van pulls up and hands me this:




Woohooo!!!! My new radiator, fan, mount and rad hoses...



Isn't that a thing of beauty?



Timing is everything aint it? The parts arrived about 30 min before a soggy looking biker.



Clint has come all the way from Rotorua for the weekend just to give me a hand firing up the 640. What a champ!

We started with a coffee and bit of standing around sizing up where to start, and then is was time to bust out the spanners and get down to business. Clint is a demon at swinging a spanner. he's like a tazzy devil with a rachet in one hand and hex bit in the other.



Before we started adding the new parts Clint whipped the inspection caps off and checked the valve clearances. All good, no adjustment needed.

Within a few minutes we had the new radiator in place, Battery bolted back in, filled with water, just about ready to go...




We set the tank up on a table and joined up some fuel hose so it coul reach. We also connected the dash back on so we could see what was going on.



I turned the key on and the dash lights up. This was the first time it's had power for 10 months. The first thing I see is the odometer...



After getting a few snaps to record it, we turned the motor over for a while without the spark plug to circulate the oil and water.

The plug went back in, and with a bit of extra help with some jumper leads... and just on 2:00pm... this:



It was about here we stopped for a celebratory beer or 2.

We were doing well so far, and had reached the first goal... I had honestly expected (and was prepared) for it to take us most of the weekend just to get it running, instead we had it going in a few hours. So what now? ok... New plan: Give it an oil and filter change.

We ran the bike on the stand let it heat up, and ran it in gear to stir up any gunk in the gearbox. Once we got 4 bars on the temp guage we shut her off and dropped the oil. and started doing an oil change. Ye gods... 2 filters, an oil screen, 2 sump plugs a drain plug in the bottom of the frame and another filler plug at the top. (who the hell thought up that system?)



With the oil and filter change done, we started it again and rechecked the oil level. It quicky settled into a smooth idle and sounded and felt really good.

Ok, so we've got it running and given it an oil and filter change... now what...

The new plan: get it rolling under it's own steam... and get in a few quick laps around the house.

So... we need to start bolting bits back on. We installed the new radiator fan and mounts, as well as fitting the tank bracket and mounting the tank properly.



Once we had run out of loose bits, we started on straightening the front end while emptying a few more beer bottles.

After dinner and several more beers we went back out to the shed and carried on straightening up the front end. We unbolted the triple clamps and reset the forks. All good, but the bars still wouldn't sit quite right.

We decided to remove one of the the sets of bars risers and found that one of the main bolts to hold the handle bars had a big bend in it. We thumped it back into line, shortened them by 20mm and bolted the bars back up. loosen adjust and rest hand guards, levers and controls. And hey presto. 1 straight front end... That was easy..now what?

We thought we'd have a crack at the front subrame. A bit of tweak here and there with a crow bar and some serious leverage using a honking great big sash cramp we managed to pull the front almost into line.

We got the right hand side to line up with the tank bracket, and almost had the left hand side whenl.. crack... we snapped the subframe....

Ahh well i've got a new one coming anyway.

At this point, we'd pretty much run out of bits to bolt on and were pretty beat and all that drinking has worked up a thirst. So we decided to call it quits for the night and go and have... some more beer..

At the end of saturday night, we left her looking like this:


kiwipeet screwed with this post 04-03-2011 at 09:41 PM
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Old 04-03-2011, 05:04 AM   #13
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Proud of you lill bro, keep up the good work.
Help yourself to the tool cupboard.
Hey fulla. How the hell did you come up with that name?

kiwipeet screwed with this post 04-03-2011 at 01:35 PM
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Old 04-04-2011, 03:01 PM   #14
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Talking Errr thanks...

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... Help yourself to the tool cupboard.
AHahhahaahah ahhhh

I love that you think your tools have ever been safe...


kiwipeet screwed with this post 04-04-2011 at 04:26 PM
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Old 09-19-2011, 12:32 PM   #15
NordieBoy
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Worn slide guide or needle jet?
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