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Old 12-28-2011, 03:14 AM   #46
Droptarotter
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Glad to see the racks fit ok.
Cheers
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Old 12-28-2011, 05:49 AM   #47
juames
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Old 12-28-2011, 06:15 AM   #48
dlh62c
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If your thinking of repainting the tank and plastics. I'd go for the Zebra stripe Daktari paint scheme.

daryl
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Old 12-29-2011, 12:50 PM   #49
funrider
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640 project

Just got back on sight this morn. great progress Dave, looking pretty sweet, Paul did a nice job on that tank. Will stop by for a closer look.
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Old 01-05-2012, 09:37 AM   #50
overlandr
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Hey GB, just for the record, found this linky to a set of Sebrings in .de that look similiar to yours - but only similiar!
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Old 01-05-2012, 07:16 PM   #51
gunnerbuck OP
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Originally Posted by overlandr View Post
Hey GB, just for the record, found this linky to a set of Sebrings in .de that look similiar to yours - but only similiar!
Those mufflers look identical to what I had, the head pipes look like they are less refined, possibly an earlier version... So that mystery is solved, thanks...

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Old 01-07-2012, 08:22 PM   #52
gunnerbuck OP
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A little more progress...

The photos may go down for a few days as I'm close to my bandwidth limit..


I decided to replace the rear disk with a fresh one...

I noticed the passenger foot peg bracket was bent... Must of took a pretty big hit as those brackets are strong...

Lucky that I have a spare kicking around...

The battery that came with the bike was too big so I ordered a cheap Gel to replace it...

I added some padded tape to the hold down bracket..

And on she goes, no battery bounce here...


The low fuel sender had a broken wire so I ground the base plate down enough to expose some end for soldering and then coated it with aquaseal for extra support..



I popped the top off the carb and noticed some needle wear so I figured the guides were also worn...



Popped the main jet out to release the guide and noticed it was way overkill, 172.5, way rich... I replaced it with a 155, the bike comes stock with a 152.5...

The slide and guide are well worn {right} past the marks so I replaced those...Also the needle and needle jet{emulsion tube}are replaced...


And a new crossover line and some blue foam to support and stop from chafing...

Next is to fire it up and see how it sounds, stay tuned....

f

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Old 01-08-2012, 12:20 AM   #53
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Test Run

Here is a bit of Video:
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Old 01-08-2012, 12:26 AM   #54
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Sounds great. Nice work on the jetting.
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Old 01-08-2012, 01:48 AM   #55
makazica
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Great work, glad you have it runnin'!!

M.
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Old 02-05-2012, 03:15 PM   #56
gunnerbuck OP
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Picture Time

OK, I'm pretty much finished this project other than a bit of saddle time tuning... There will be a few things I'll be replacing in the next bit but the bike wont really look any different than it does now.... So before I get it dirty here are the pictures:


I'm happy with the results...



Black does give it a different look....









My 152,000 KM bike vs My 28,000 KM unit...

I almost like the black look better...

In a ride comparison my project 640s engine is noticeably smoother than my prime bike, this could be partly due to a tighter piston fit in the bore.... Another thing I notice is how the project bikes front end has the pogo stick effect, especially when braking... I'll solve this with some heavier springs up front, my prime bike has 950 springs in it....
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Old 02-05-2012, 07:49 PM   #57
shevthump914
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Wowsers, bike looks AWESOME!!!!!!!!!!!. I will look into some nice white KTM decals for it.....


Paul.S
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Old 02-05-2012, 07:58 PM   #58
slackmeyer
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Quote:
Originally Posted by gunnerbuck View Post
In a ride comparison my project 640s engine is noticeably smoother than my prime bike, this could be partly due to a tighter piston fit in the bore.... Another thing I notice is how the project bikes front end has the pogo stick effect, especially when braking... I'll solve this with some heavier springs up front, my prime bike has 950 springs in it....
I guess the project bike has 43mm forks, and thus different springs, right? I've got the stock springs from my 950 hanging around the garage, if they would fit, they're yours.
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Old 02-05-2012, 08:04 PM   #59
ChrisC
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I guess the project bike has 43mm forks, and thus different springs, right? I've got the stock springs from my 950 hanging around the garage, if they would fit, they're yours.
I'd say that since both are '03s, both are 48mm. That being said, the 950 springs should work (and if GB fails to need them, I could put them to use...)

Chris
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Old 02-05-2012, 08:13 PM   #60
slackmeyer
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I'd say that since both are '03s, both are 48mm. That being said, the 950 springs should work (and if GB fails to need them, I could put them to use...)

Chris
Oh, ok, I didn't reread to find the year. I thought the adventures with 48's had double discs on front, like the 950 ADVs.

Anyway, the springs are from an 06 950, which means they'd need a 20mm spacer to be the correct length for a 640. If GB doesn't want them, I'll send them your way.
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