Project bike: 2007 KTM LC4 640 Adventure

[kiwipeet]

Originally Posted by The third Amigo

... Help yourself to the tool cupboard.

AHahhahaahah ahhhh

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

[NordieBoy]

Originally Posted by kiwipeet

Engineer was happy enough.. but didn't like the dings in the front rim. It will need to be replaced before I get it certed.

Mustn't be a very good engineer. Doesn't know that KTM640A rims come pre-dented from the factory.

It's a safety thing. The rim dents, to save the tube from pinch flats.

[draincleaner]

Mikey will be looking down and saying at last your learning .All you need now is the cooker, frying pan a little bit of Chilli and 2 sausages.
Bloody good work Peet and Clint,

[kiwirob]

Originally Posted by draincleaner

Mikey will be looking down and saying at last your learning .All you need now is the cooker, frying pan a little bit of Chilli and 2 sausages.

i love the comments as it sounds just like when mike was around thanks Trev

Originally Posted by kiwipeet

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

ahahahahahahahaahha wash your mouth out peet he doesnt know that i am using them all

[warewolf]

Fantastic. Good work there, Clint!

Originally Posted by kiwipeet

Engineer was happy enough.. but didn't like the dings in the front rim. It will need to be replaced before I get it certed.

Organise the inspection for a Satdy when Clint is in town, slip on his front wheel

At WOF time they just say, "if anyone asks, you dented and cracked that rim AFTER we gave you the WOF, okay?" They also look twice at the MX front tyre but they are DOT approved so legal.

EXC >= 2003 wheels fit straight on, you just have to remove the front EXC spacers/bushings and cut 4.5mm off the Adv ones (ditch the second disc).

[kiwipeet]

Originally Posted by warewolf

Organise the inspection for a Satdy when Clint is in town, slip on his front wheel

... EXC >= 2003 wheels fit straight on... (ditch the second disc).

Hmmm I did consider that, but the problem is it needs to be "as new" the bike came with twin discs as standard, therefore will need them to pass cert. Any deviation from standard configuration will complicate and prolong the process.

However if someone happens to have a mint condition 950 rim I could borrow...

Engineer also wants receipts/invoices as a paper trail. He's a nice guy but he's not taking any shortcuts.

[kiwipeet]

Umm I think it's my credit card...

Today I ordered a brand new replacement front wheel from Woodies Wheel Works in the US.

Zach has been great to deal with and reckons they can have it on it's way tommorrow

Awesome stuff.

[clintnz]

Originally Posted by kiwipeet

Umm I think it's my credit card...

Today I ordered a brand new replacement front wheel from Woodies Wheel Works in the US.

Zach has been great to deal with and reckons they can have it on it's way tommorrow

Awesome stuff.

Nice! That's pretty speedy service. Once the credit card has been extinguished you'll be able to get a smaller rim laced onto your existing hub for motard duties

Cheers
Clint

[kiwipeet]

Originally Posted by clintnz

Nice! ... you'll be able to get a smaller rim laced onto your existing hub for motard duties

Hmm I was thinking It would leave me with a spare, but it would always be weak/wonky/2nd best and not as good as what I'm getting... but I like your idea better

[warewolf]

Originally Posted by kiwipeet

FLASHER CPL.FRONT L/S REAR R/S - 5841402500030 (missing a blinkykator... will include in next order.)

Check if the EXC ones fit - I've pilfered various bits from my 200EXC but not a complete unit - and if so, try a wanted ad on trademe. Should be plenty of EXC blinkers kicking around unused in sheds, that are extremely unlikely to ever be fitted to the bike.

[kiwipeet]

Not a lot of progress lately.

Last weekend I was in Welli for a breif visit and picked up a few bits and bobs. Some loctite, some spare indicators and a small euro nuts and bolts pack.

Today I picked up the subframe from the welder after more than a week of being jerked around. Each day I was told come back tonight, then come back tommorrow... 6 visits later I had kind of lost my sense of humour about it.

At lunch time today I gave him some pretty clear instructions that I would be picking it up tonight whether it was done or not.

The message must have got thru, because it was done when I arrived after work, but I can't say i'm impressed with his workmanship.



He seemed a bit hurt when I asked if the apprentice had done it...

Once the engineer has inspected it tommorrow I can start to reassemble the bike so I can get the brakes tested. fingies x'd.

After dinner I spent a few hours in the shed, and finished my bodgy job fixing the headlight bracket. It just needs a bit of sealant to glue it all back together.

[kiwipeet]

A parcel arrived today

containing...



Thanks to woodies for an excellent service.

[kiwipeet]

A big night tonight in the shed.

Got the subframe back on and started reassembling the bike.



All going good except for 1 wire which I'm not sure if it should be attached to the positive terminal, or grounded to the frame.

without it the starter turned over. once we added it to the positive, with a bit of bzzzttt... we got nada... crap...

We found a thoroughly sizzled fuze, in the circuit for the headlight but pretty sure this was before my efforts.



So after updating this, my bedtime reading will involve a detailed schematic of a wiring diagram...

[kiwipeet]

shit shit shit shit...

all brown wires are earth/ground.



fuuuuuuuuuuuuuuu!%$ki

[clintnz]

Bugger! Better trace that wire back & work out what's fried.

Looks like they have just migged that subframe. It'll be stronger than stock but a 1/2 skilled TIG operator or a good man on an oxy acetylene torch would have done a much better looking job. Anybody that feels the need to grind back their welds on a job like that shouldn't be describing themselves as a professional welder IMHO.

Cheers
Clint