Picked up a new 2005 KTM 640 Adventure (cost AUD $14,200 on the road) on the 4th of March thanks to this forum which I have been following for some months now. The choices: I checked out the XR650's, DR650, F650 Paris Dakar, KLR 650 and the KTM 640 Enduro. Only managed to score a ride on the KLR, no one else had a demo, the first time I braked nothing happened so I really grabbed a handful and the forks dived so severely that I nearly went over the handlebars and thought these forks and brakes need some work (it was my first ride on this class of bike and I had just stepped off an ST1100) it was fairly smooth and quiet compared to the Adv. Like many have said the Adv is the only bike that comes with all the good stuff right out of the box, expensive but still good value. Running in: I have now ridden 1,300 Kms and completed the 1st service at the dealer which I had included as part of the deal, with me allowed to watch, again based on the advice of someone on this forum, more on this later. The first tankful returned 21.4 Km/litre, the second 22.6 Km/litre and the third 21.5 Km/litre, mainly riding around town and the local hills, no dirt and I was keeping the revs under 5,500 rpm with the occasional burst above that when changing up through the gears. Fuel used Caltex 95 octane. First Impressions: The vibration and general noise level have improved since new though the standard muffler sounds like a car muffler with a leak. The seat is not that bad if you sit towards the rear part where it is broader and my other bike is an ST1100. It needs a fairing, a 1000 km day would be hard with the wind noise and just hanging on to the bars. Seal Savers: I got the dealer to fit Seal savers (cost AUD$13.95) as part of the pre-delivery, you can see them in the mudflap pics. Topbox: The first thing I did was fit a topbox as I use my bike every day and need somewhere to put my helmet, gloves and cable lock plus carry other stuff when the need arises. I picked the GIVI E33 (cost AUD$162), it came with a mounting pad and all the hardware required to bolt straight on to the standard Adv rack. It took about half an hour to mount and I would recommend it to anyone. It has one key which both locks the lid and the box to the mounting pad. I velcroed two 5mm thick dense foam mouse mats to the bottom to absorb some of the vibes Mudflap: The next mod was a mud flap as I ride in all weather conditions and I would rather not turn up at work covered in crap picked up off the road plus the motor stays a little cleaner. I used a document folder from the local stationary shop (cost AUD$2.32) and some M4 bolts cut to the exact size so they would not foul the tyre with nyloc nuts. Staintune Muffler: The original muffler had to go, experience with Staintune on previous bikes was better sound, power/torque and reduced fuel consumption so I had this fitted at the first service (cost AUD$520). Both of the mounting holes in the muffler had to be elongated and it bolts to the frame at the rear mounting point. The middle bracket does not get used. The original muffler weighed around 6Kg and the Staintune is probably around 3kg. The idle is smoother, it sounds good, you can actually hear each engine pulse instead of a waffling noise and pulls better from low revs. THe muffler is made of stainless steel and comes with an insert, I tried it without the insert and it was too loud so the insert went back in. Fuel consumption check still to come. Clear Film: I bought 2 meters of thick clear film and so far have applied three layers to the headlights (about 1mm thick in total) and one layer to the upper part of the forks. I plan to cover the tank front and lower with 2 or three layers as well. Fork Stop bolts: After having the bike for 3 days and 500 kms I noticed one of the bolts that stops the fork from turning too far to the right was missing and the left one was loose so I replaced these with 40mm bolts and two nuts the originals were 25mm so far they have not budged. Foot Brake Cam Bolt: The foot brake has a cam to adjust the height, the bolt holding this on was torqued too tight and when loosening it I could feel the hex rounding off so I replaced it with a bolt with a bigger hex socket. You can see the hex socket on the brake pedal as well does not look too healthy and I have not touched it. The muffler bolts were not much better, KTM need to look at the quality of their fastners. Air Box Bolts The bottom air box bolt spun when I tried to undo it, the mechanic used a rattle gun at the first service to jerk it loose. The pic shows some green stuff on the nut which looks like someone at the factory tried to fix the problem unsuccessfully. Right now its just done up not tightened at all. Any ideas on how this can be fixed. Chain Adjusting Bolt Have a look at the left chain adjuster the bolt is bent, the nut is at an angle and wobbles when turned, how did this happen? I also bought some male electrical connectors to fit the one on the dash http://www.powerletproducts.com/products/plugs_sockets.php And have ordered a set of alu panniers and rack from Munn Racing, its cheaper by AUD$600 to air freight from Texas than to buy locally in Perth. http://22.214.171.124/munnracing/hardparts/hardparts.cfm The 1st Service: I organised this as part of the deal, normally I would have done it myself. The mechanic was well meaning and experienced but had never worked on an Adv, he did not know there was a second oil filter behind the brake lever and he did not know you had to bleed the system, I showed him the owners manual. He then overfilled the oil according to the oil window though I only paid for 1.9 litres. Is there a way to drain the excess oil without having to repeat the complete oil change procedure. The oil used was Mobil 4T 20w50 a mineral oil, the manual states 10w50 synthetic, apparently they use Mobil oil in all their bikes including R1's (its a Yamaha/KTM dealership) and have not had any problems. With the valve clearances he said KTM had advised them to loosen the locknut, screw the adjuster in until it lightly bottomed then back it off between an 1/8 to 1/4 turn. 1/4 turn equates to .006" or .015mm. He did not use a feeler guage at all to check. Has anyone else heard of this being done. I plan to pull the bike apart at the first opportunity do an oil change and check everything again. Overall a great bike and I am learning and having fun.