640 Refresh

Discussion in 'Thumpers' started by juames, Mar 19, 2013.

  1. juames

    juames Have Fun, Don't Die!

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    In December I decided that this winter I would give my 640 Adventure some attention. I've owned it for a full season now, and put about 10,000kms on...doing virtually nothing to it except change the oil twice. It has been a blast to ride and never let me down, except during last years Roaming Rally when I took it swimming. Even then after I removed the water from all the places it's not suppose to be, she fired right up as if nothing had happened! I don't have any major work planned...mostly cosmetic (new paint) and preventative maintenance. Basically check all the wheel, suspension, and steering bears. Water pump rebuild, check cam roller bearings, clean carb, replace a few broken bits, etc. Basically give it a good once over that I really didn't do when I bought.

    So here is how she looked before the snow started to fall in December. Not too bad really...a few battle scars.
    [​IMG]

    About 45 minutes later, this is how she looked naked. Can't believe how much lighter without the plastic.
    [​IMG]

    And this is how it sat in the garage all winter, until we started to have some signs that spring might actually come. So much for my plan to slowly work away on it over the winter.
    [​IMG]


    ...
    #1
  2. bmwktmbill

    bmwktmbill Traveler

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    You're gonna need more room on the right.
    b
    #2
  3. juames

    juames Have Fun, Don't Die!

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    Definitely...the sad reality of having a single car garage...only way to get the car in as well during the winter months. I'm not complain though...small garage is better than no garage. Just wish it was a bit warmer in the winter.
    #3
  4. CSF

    CSF Been here awhile

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    Nice! Looking forward to seeing how this progresses. When are you thinking you'll have it all ready to go and back on the road?
    #4
  5. juames

    juames Have Fun, Don't Die!

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    I'm hoping for next week. :ricky

    U?
    #5
  6. juames

    juames Have Fun, Don't Die!

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    First thing that I decided to tackle was the water pump. And since the rocker cover has to come off, the area needed a good cleaning.
    [​IMG]

    And from the looks of things it was due for a rebuild. The seal was on it's way out.
    [​IMG]
    [​IMG]

    Chocolate milk bad...
    [​IMG]

    Bearings were still nice and smooth with no play, but the shaft was starting to show some wear.
    [​IMG]
    #6
  7. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I trying to do the same thing on my 620. Planned on taking all winter to rebuild her - and now I'm in a rush to get her put back together. Here's how it looked a few weeks ago:

    [​IMG]

    Now, I've taken the back wheel off to replace the back tire.


    I did the water pump on mine while it was apart. I found that I had much better luck putting the new seal in with my thumbs. I tried using a press, and it just distorted it.
    #7
  8. juames

    juames Have Fun, Don't Die!

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    Found the same thing with the seal... Have to take your time and be gentle with it.
    #8
  9. juames

    juames Have Fun, Don't Die!

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    While I had the rocker cover off I thought I'd check the cam roller bearings. Turns out they are good as new! Smooth, and zero play.
    [​IMG]

    Think they are original, no punch marks. [​IMG]
    #9
  10. juames

    juames Have Fun, Don't Die!

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    Inspected the ignition switch wiring, as they have been know to fail. But all the solders are still in tact. [​IMG]

    Decide to take some preventative steps just in case. [​IMG]

    [​IMG]
    #10
  11. Deadly99

    Deadly99 Fast and Far

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    :lurk
    #11
  12. CSF

    CSF Been here awhile

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    I like the silicon fix, that's some good preventative maintenance :thumb.
    #12
  13. juames

    juames Have Fun, Don't Die!

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    I saw the pictures of broken connections in your thread and figure it was worth the time to take a look, and the silicone should add some extra support.
    #13
  14. shipwrek12001

    shipwrek12001 Shipwrek

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    your body work looks really slick.... do you have a Graphics kit for it or you running just colour?
    #14
  15. juames

    juames Have Fun, Don't Die!

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    Ted did such a nice job on the paint, I think it would be a shame to cover it over. Might add a couple small things.
    #15
  16. CSF

    CSF Been here awhile

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    Got some pics of the body work, or am I missing something?
    #16
  17. juames

    juames Have Fun, Don't Die!

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    Shipwrek jumped the gun on me, haven't posted any yet. :lol3
    #17
  18. juames

    juames Have Fun, Don't Die!

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    Still have a few things to do before she is ready to roll, but here are a few sneak peaks.

    Some shots from the master as he was doing his work! Thanks Ted! :clap
    Fairing
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Tank
    [​IMG]
    [​IMG]

    Fenders/side panels
    [​IMG]
    [​IMG]
    [​IMG]
    #18
  19. CSF

    CSF Been here awhile

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    wow! very nice work, I like your color combo.
    #19
  20. Deadly99

    Deadly99 Fast and Far

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    [​IMG]
    #20