2005 KTM 640 Adventure

Discussion in 'Thumpers' started by desmonc, Mar 22, 2005.

  1. ozadvntr

    ozadvntr Planning that trip, again

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    Warewolf,

    Yes, Dalby Moto will do the kit. Ring them on 617 46621211 or tryDalby Moto

    The guy to initially talk to is Justin, tell him I put you onto him. You will very rarely get hold of Craig Hartley, he is always away doing something bike related.

    I chose the SX muffler, got a deal on it.

    Mick
    #21
  2. desmonc

    desmonc Bike Rider

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    The bike is light and I got used to the height fairly quickly, I am 180cm or 5'11'' and I find that if I slide forward where the seat is narrower and at its lowest point I can get one foot flat on the ground.
    The headlight plastic film is 1.5mm thick and no one in Perth stocks it or is prepared to order any more due to lack of demand, they have to order it by the roll.
    The simplest option with the high front guard is to remove one disc.
    If you are going to use soft luggage and the Akra muffler you will need to get a bracket welded to the muffler to fit the rubber stops that prevent the side covers coming into contact with the muffler, the Staintune already has this bracket or get the Pannier rack only as protection.
    The motor runs lean with the Staintune plus insert, I screwed the slow speed mixture screw right out and it made no difference. I have ordered a smaller Pilot air jet and some larger Main jets following advice from the experts here.
    The Oz Mikuni dealer has jets for half the price of KTM.
    http://www.iwt.com.au/index2.html#
    #22
  3. desmonc

    desmonc Bike Rider

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    I got 2 x 41 litre because I have to carry water, food, tent, fuel, etc. should not be too much of a problem out in the bush just have to remember not to split lanes when leaving the city.
    #23
  4. Trevor S

    Trevor S Cap'n Flatulence !

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    Out of curiosity, would an full Ackropovic exhaust system from an '02 model fit an '05 model ??
    #24
  5. desmonc

    desmonc Bike Rider

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    #25
  6. ozadvntr

    ozadvntr Planning that trip, again

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    Who has one for Sale? :evil
    #26
  7. Trevor S

    Trevor S Cap'n Flatulence !

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    HA ! Not telling :wink:
    #27
  8. BUTTERBALL

    BUTTERBALL Never ending kid saga...

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    :puke1
    #28
  9. desmonc

    desmonc Bike Rider

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    N.E.P cc3 Cruise control

    Modified a NEP model cc3 to fit the Adv.
    The cc3 model is designed to fit bikes with dual throttle cables and has a rectangular bit on the bottom which fits between the cables to lock it in place.
    1. Enlarge the opening to fit over the throttle shaft, I used a round file and removed about 1mm, file once and measure often or you might take too much off.
    [​IMG]

    2. Replace the bolts in the throttle housing with 40mm's and nyloc nuts.
    3. Make a small Z shaped bracket and rivet to the bottom of the cc.
    [​IMG]

    4. Trim the rubber grip to clear the cc, I butchered it without any regard for aesthetics as I will be replacing them with heated grips.
    [​IMG]

    5. Fit the cc over the throttle with the bracket positioned between the two bolts and do up the nuts until they just touch the bracket. If you overtighten the cc will distort and bind.
    [​IMG]

    This solution works, is simple to build and can be removed by undoing one nut and sliding it off. These things are like heated grips, once you have had them on a bike you can't do without.

    Special Tools
    Some tools that I have had to make or buy for the Adv.
    1. Axle guage - Used when adjusting the chain to make sure the axle is square with the swingarm pivot. The marks on the swingarm are out by about 3mm. It could also be used to measure chain stretch. I saw the KTM part for $30 on the Munn Racing website and decided to make one out of stuff I had lying around, cost nothing.
    2. Right Angle screwdriver - Used to adjust the idle mixture screw. Bought from the local bike shop (AUD$55), its all metal and has a silver collar with marks that can be set in any position independant of the handle to measure the number of turns.
    3. Brass punch - Used to adjust the pre-load. Could not find a brass punch of the right length (250mm), diameter (8mm), the closest was 290x19mm too big and heavy. I got some brass rod from a local fabricator tapped some threads into one end and put a steel screw in to stop it from mushrooming on impact, the soft end goes against the shock.
    [​IMG]
    #29
  10. desmonc

    desmonc Bike Rider

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    Thanks Colin, Do you have a link to the KTM-Sommer blanking kit, I could not find it in their catalog.
    #30
  11. Trevor S

    Trevor S Cap'n Flatulence !

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    About the forth item down

    Courtesy of babelfish,

    ADVENTURE 640 2004/05

    "Who would like to deactivate the secondary air system (SLS) for the remote travel employment or cultivation of an open sport muffler, needs the following parts:"
    #31
  12. Happy Pants

    Happy Pants KTM 990 Adv UK

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    Desmonc


    I have an '04 ADV 640 R and have just fitted the Sommer tuning kit and the 2 plugs which blank off the SLS & EPC systems. It has had a good effect so far but only ridden bike once last night after fitting so still evaluating.

    I'll send you more details if interested

    Cheers

    HP
    #32
  13. bikemoto

    bikemoto Tyre critic

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    G'day Mick,

    Do you know where the parts came from? Was it simply a matter of choosing suitable bits from other KTMs? Seems to me that the fork guards are pretty universal, in terms of mounting holes.

    So what colour is the fender? What about the fork guards?

    What did you do about the brake line? Did you turf the second disc? That's the suggestion I've got from my dealer, but I would expect that the master cylinder would need to be changed since it would only be driving half the amount of brakes.

    I'm trying to work out if it is easy enough for me to source all the individual bits locally, or if I should just buy a whole kit from someone who's sorted it all out.

    Thanks.
    #33
  14. Mack

    Mack Gone, but never forgotten. RIP, Mack...

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    Warewolf, lot's of info in Orange Crush on the high fender conversion. Some recently posted a parts lists. At a minimum the fender is available in silver, black, and orange, though none are painted that I know of. Most of the guards if not all, are black, but a number of stickers are available, some in different colors, most from the dirtbike side of KTM, but they all fit the same.

    I think Jimmy ended up using a 125 master cylinder when he converted to a single disk.

    PS: is that pic in front of the war museum? Man I need to get back down there.
    #34
  15. desmonc

    desmonc Bike Rider

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    Thanks for the offer, I got busy over the weekend and did the job myself.
    #35
  16. desmonc

    desmonc Bike Rider

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    Mikuni BST 40 Mods

    Its amazing what $15 in parts and a few hours work can do, the adv has been transformed.

    First I removed the Snorkle, this just pulls off and the hole in the airbox is about twice the size of the snorkle outlet.
    [​IMG]

    [​IMG]

    Next I removed the carb, this is fairly easy, loosen the four clamps, remove the throttle cables and disconnect all the plumbing and electrical connectors and pull the carb out from the kick starter side, the two boots will come off with it.
    Take the plastic top off, two screws and move the circlip on the needle down one notch, 4th from the top. The white plastic spacer is a tight fit, position it resting in the gap of a vice and lightly tap with a screwdriver handle, it only needs to move a tiny bit, fit the circlip, turn the needle around a light tap from the other end to seat the spacer against the circlip
    [​IMG]

    [​IMG]


    Next remove the float chamber, two screws and replace the main jet with a 155.
    [​IMG]

    Then I removed the pilot AIR screw from the carb inlet and replaced it with a 1.1
    [​IMG]

    I also took the pilot fuel jet out to take a picture and get the part no. which is according to Sudco - OEM/N151.067
    http://www.sudco.com/catalog105/065.pdf

    [​IMG]

    Getting the carb back in was a little harder, I put the engine boot on first then the carb, then I removed the clamp from the carb side of the airbox boot and squashed the airbox boot into place. I opened up the clamp that I had removed completely and fed it around the boot and tightened, reconnect all the hoses etc and the job is done.

    I started the bike warmed it up and went for a ride, first impression was that I was on a different bike, it felt more powerful and torquey through out the rev range and I could hold a higher gear everywhere. Before 5th/top gear was unusable under 80 kmph or 3500 rpm, now I can get as low as 60 kmph or 2600rpm. I rode over 200 km's and could not get it to misbehave regardless of throttle position, revs or speed. Max speed was 160 kmph at 7000 rpm it would get there fairly quickly but would not go over 7000 in 5th, I tried three times in different spots (it was windy) though in the lower gears it revved past the redline. A larger main jet might help with power at the top end.

    The backfiring has been replaced by a growl and a soft popping sound.
    The pilot mixture screw is 3 turns out, it started to hesitate at 2 and then 4 turns. Idle speed is set to 1400 rpm. The bike now idles quietly and smoothly, I can leave my gloves on the seat while I put my helmet on and they do not walk off the seat. After experimenting with various mixture and idle speed settings I found that with a higher idle speed and leaner mixture there was a momentary hesitation just off idle after idling for about 10-15 seconds which could cause a stall.

    I did buy two other mains a 157.5 and a 160, might try them later on though I dont think the low to medium speed running is going to get much better.

    In summary the changes are
    1. Staintune Muffler with the insert
    2. Snorkle removed
    3. Main jet to 160 (157.5, 155) (P.No. N100/604<?XML:NAMESPACE PREFIX = U1 /><U1:p></U1:p> ) see below
    4. Pilot air jet to 1.1 (P.No. BS30/97<U1:p></U1:p> )
    5. Needle on the 4th notch

    **** 5000 km - I replaced the 155 main jet with a 157.5 through the hole in the bottom of the float chamber, used a mirror and a 1/4 ratchet with a screwdriver bit.
    There is a noticeable improvement right through the rev range especially above 5000 rpm, the top speed is now 170 kph @ 7500 rpm and it gets there quicker. Amazing, after the first lot of jetting changes I did not think it could get any better, will have to try the 160 main next.
    Fuel consumption increased on average by 1/2 a kmpl after the first lot of jetting changes.

    **** 6500 km - Fuel consumption with the 157.5 main has not changed compared to the 155 if anything it may be using slightly less fuel.
    Fitted a 160 main jet, spun the carb this time(it only turns about 20 degrees which makes it easier to get to the main jet), it looks difficult but the bundle of wires that gets in the way on top has enough slack to be pulled up out of the way, overall bike feels more responsive, top speed is 175 kph and vibration is down over 5000 rpm.

    **** 10,000 km - Fuel consumption with the 160 main jet has not changed, city riding only gets 21 km per litre, mixed city, highway and dirt is between 20 and 21 km per litre - excellent.
    I experimented with putting the snorkle back on, the bike felt sluggish and after idling for a couple of minutes at the lights it would stall when trying to ride away so off it came. With the free flowing Staintune muffler and the bigger jets the bike needs to flow more air than the snorkle will allow.

    Fitted Loaded's mixture screw as well, 2.25 turns out, this thing works.
    http://www.stenhouseracing.com/

    [​IMG]

    [​IMG]

    I bought the jets from the Oz Mikuni dealer Ian Williams in South Australia, they were in my mailbox 2 days after I placed an order. http://www.iwt.com.au/mikparts2.htm
    You need the Part numbers to order. Thats why I took a picture of the Pilot fuel jet.

    Drilling the slide and cutting coils off the spring are irreversible and I won't be making those changes until I have spares on hand to play with.

    Thanks for everyone's help and advice and
    Flanny's Guide - http://www.motorally.ca/English/OnTheWeb/Links.htm
    and http://www.iwt.com.au/mikunicarb.htm


    If any new 05 Adv owners are sitting on the fence over this one jump off and do it now, its the most satisfying change I have made so far.

    Secondary Air System
    I also removed the SAS except for the metal pipe and a hose, I first plugged the metal pipe with some rubber but this blew out so I put the short hose back on and plugged it with a bit of 12mm rod.

    [​IMG]

    [​IMG]

    [​IMG]

    It has cleaned up that side of the engine. I don't believe this makes any difference to performance because I had already tried removing the vacuum feed to the valve and did not notice any change.
    #36
  17. desmonc

    desmonc Bike Rider

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    From the picture in the Sommer catalogue it looks like the 04 guard and a longer brake hose @ 250 euro plus postage, it would probably be a lot cheaper to buy the guard and hose and fit it yourself.
    #37
  18. bikemoto

    bikemoto Tyre critic

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    Awesome! Shoulda thought of that, given the front end has been ported from the 950.

    Yep, sure is. This is the view facing the other way:

    [​IMG]
    #38
  19. bikemoto

    bikemoto Tyre critic

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    Mate, I'm going to have to bookmark this. I will save my pennies and by the time the stock muffler needs a re-pack I'll go for the Staintune.

    Great documentation of the process, btw.
    #39
  20. Surly

    Surly surly adventurer

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    Mar 17, 2003
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    Location:
    Salem, OR
    I'd enjoy some details. Wouldnt mind doing the deed to my 05 :ear
    #40