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Old 07-10-2014, 11:04 PM   #1
gunnerbuck OP
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Joined: Nov 2005
Location: N.V.I, B.C.
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New 640 Build from the Ground up

***This photos in this thread will reappear on the 18th of the month as my monthly bandwidth gets reset back to 10gb on that day.. I switched photo hosting sites on the last pages in order to continue with picture updates after having 2 months in a row where my photobucket storage site bandwidth was exceeded...***



A friend of mine bugged me about selling my project bike to him as he has been unable to find any on the used market.. I told him that the only way I would sell was if a 640 frame came up on the market with title for Canada...

Well, a frame with title came up in eastern Canada {thanks to inmate CSF} so I purchased it and had it shipped to B.C.... This was the final piece of the puzzle to build a complete bike from scratch...

I said goodbye to the project bike as it went to a happy new owner:



It starts off with the frame bits, the mainframe was black, subframe was dark grey and the kickstand and peg brackets were light grey... A cleanup and a bomb with paint changed it all to black...

The mainframe is off a 2007 Adventure, the subframe is off a 2000- LC 4- 400 and the center stand + peg brackets off a 2003 Adventure...



My spare front wheel from a 525 had a wow in it so I laced in a new excel rim

I may of been able to true the old bent rim back to spec but I figured for the time it would take, I might as well lace in a new one...

gunnerbuck screwed with this post 09-10-2014 at 09:35 PM
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Old 07-10-2014, 11:18 PM   #2
Alik
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Subscribed for some garage porn. ;)
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Old 07-11-2014, 06:39 AM   #3
Kawidad
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I'm in too.

Lot'sa pics too
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Old 07-11-2014, 06:52 AM   #4
michael1968
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In!
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Old 07-11-2014, 11:39 PM   #5
gunnerbuck OP
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Location: N.V.I, B.C.
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Assembly


The bottom triple is from a 06 Adventure, I knocked the old bearing off with a dremel cut and a cold chisel

heated the frame

Retrieve the new bearing races from the freezer

With a cold bearing race and warm frame they tap in a bit easier






I warmed the roller bearing

And it easily pressed on the stem

Bottom greased up and in place

Top triple in place, it is from an 03 Adventure

2004 400 FE Husaberg forks which I rebuilt and shortened by 1" to give 11" of travel.. The bars are from an 03 Adventure..

Forks on

Wheel, subframe, stand and peg brackets in place, bars mounted to Rox risers, that's where I quit for today
f

gunnerbuck screwed with this post 07-13-2014 at 11:23 PM
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Old 07-11-2014, 11:59 PM   #6
sir phily
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Well done mate this should be a good read,
will be interesting to see how many miles you can do on this one.

Cheers Phil
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Old 07-12-2014, 04:12 PM   #7
bobbed06
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Subscribed, and amazed that you are fitting so many different model parts to one bike.
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Old 07-12-2014, 05:37 PM   #8
Lornce
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Old 07-12-2014, 06:23 PM   #9
docwyte
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Interested in watching the build. Why'd you go with the Husa forks vs WP?
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Old 07-12-2014, 06:32 PM   #10
warewolf
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Great stuff! I'm not likely to do this any time soon, but this will almost be like watching a factory assembly job, kinda.

Quote:
Originally Posted by bobbed06 View Post
amazed that you are fitting so many different model parts to one bike.
The Euros love long model runs and modular parts, so this is relatively easy. Plenty of bolt-on swaps in the KTM Familie.

Love it!
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Old 07-12-2014, 08:20 PM   #11
gunnerbuck OP
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Quote:
Originally Posted by docwyte View Post
Interested in watching the build. Why'd you go with the Husa forks vs WP?
The Husaberg forks are made by WP and pretty much mirror the 640 fork in most respects except for the longer travel... They were needing some care so I got them at a fair price... I tore them down, cleaned, replaced all the worn bushings and the seals...
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Old 07-12-2014, 10:52 PM   #12
bmwktmbill
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Hey Gunner, I see a centerstand on this build.
Are you gonna do a kickstand too?

BTW impressive work.

bill
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The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 07-12-2014, 11:27 PM   #13
gunnerbuck OP
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Quote:
Originally Posted by bmwktmbill View Post
Hey Gunner, I see a centerstand on this build.
Are you gonna do a kickstand too?

BTW impressive work.

bill
I have a SW Motech stand that I'm debating whether to put it on one of the bikes, but after 10 yrs of center stand only I really don't think I need a sidestand...
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Old 07-13-2014, 06:47 AM   #14
rz35027
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Great stuff Gunner.
Your build threads are super valuable to folks that don't have the mechanical skills you do...
A picture speaks a thousand words. (saves typing:)) And, you have some explanations in there too!

Carry on...
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Old 07-13-2014, 07:05 AM   #15
FreeGranite
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