640Adv FCR Install ???

Discussion in 'Thumpers' started by AndyB, Apr 29, 2006.

  1. AndyB

    AndyB Lonely Traveler

    Joined:
    Dec 12, 2004
    Oddometer:
    173
    Location:
    WestbyGodVirgina
    All right then getting an FCR39,(most riding done in the woods and very tight back roads so going for the grunt the 39 gives)
    my last endo from a sputtering blubbering BST from hopping water bars that put me face first into the dirt and busted the bike pretty bad has happened. might still go over bars but not from a sputtering carb i hope.
    So looking for the beta from someone who has succesfully installed one on a '02 640Adv. i don't mind the tinkering that might go along with the install, just want to have all the parts on hand to get it done right from the start.

    ...do i need longer cables? i've read several posts of this being a problem (under bar mounted emig stab. with i think a 1" rise) where do i get them? Motion Pro?
    ...seems i read in the index that there was a fit problem,... carb hitting the stock pipes??? (stock pipe currently with cored out S.tapp can, but replacing soon, prob. just the can if there is no fit prob. with stock pipe)
    ... Jetting? i ride 'bout 500'-4500' , and i know this will will change depending on pipe, so what sizes do i start with?
    ...what about the side cover/snorkel issue(currently, snork in/screened side cover)
    ..any other install i need to know abouts?...Mucho Thanks in advance..,AndyB
    #1
  2. ktmnate

    ktmnate Long timer

    Joined:
    May 7, 2003
    Oddometer:
    3,088
    Location:
    Somewhere
    I'm not sure if the cables will fit but I have a Loadedagain 31.5mm rise with the Scotts stabilizer and no issues. It's a bit tight on the Decompression cable but it works. I wish I had the FCR. I'm keeping an eye on this thread. I might someday get that FCR and need setup info.


    Nate
    #2
  3. dzrtracin

    dzrtracin ride'n 2 live

    Joined:
    Sep 28, 2004
    Oddometer:
    3,143
    Location:
    the garage
    I would like to change up as well, i had my first episode last weekend on a stairstep hill climb, blubbering after every stair, not what ya want on a steep asent. Where ya at creep?
    #3
  4. overlandr

    overlandr Dystopist

    Joined:
    Nov 30, 2003
    Oddometer:
    5,929
    Location:
    Sydney
    I gather Boejangles had one on his 640 (now ex) with an Akrapovic setup. Don't know of anybody else out there with the setup but no doubt they are around. I'd be interested to know the jet/needle info as well. Perhaps there's something over on ktmtalk? :ear
    #4
  5. Yellow Pig

    Yellow Pig Allergic to asphalt!

    Joined:
    Oct 28, 2004
    Oddometer:
    8,311
    Location:
    Kalifornia
    Talk to Esteban. He's got one on his 99 LC-4. That thing rips!
    #5
  6. 2whlrcr

    2whlrcr gooligan

    Joined:
    Jan 30, 2005
    Oddometer:
    8,437
    Location:
    Dubuque, Iowa
    I put a FCR41 on my Duke and didn't have too many issues. The cable routing of the FCR was opposite from the Edelbrock that was on the Duke. Everything fit that Sudco sent, but it did require a little headscratching.

    That carb made a HUGE difference in how the Duke ran. Much smoother, instant throttle responce and a big power gain. I'd do it again to my Adventure, if I wasn't so lazy.
    #6
  7. Esteban

    Esteban Banned

    Joined:
    Jun 7, 2004
    Oddometer:
    5,799
    Location:
    Above Golden
    I´ve out of the loop down here in San Miguel de Allende but here is my input.

    I installed a 41 mm FCR about 10,000 miles and 3 years ago on my 99 640 lc4e. I am very happy with it. Here is my setup. (BTW, I live at 5500 feet and ride to 13,000 +)

    138 main
    OBEKR needle in middle position or one leaner.
    45 pilot jet
    squirt time at the minimum possible about 1.5 seconds if I recall correctly.

    modified KTM EXC exhaust muffler with stainless screen in place.

    16:42 final drive (I have a 17 inch rear wheel though)
    Bike works fine from slow to fast speeds

    will do all Colorado single track stuff with ease and still pull 100 + mph inidicated

    Motion Pro cables SUCK.
    I use stock cables and they work much better with less throttle resistance.
    The bent piece of steel tubing on the Mikuni cables is not perfect though but can be slightly straightened for the FCR application. Careful though as it will crack. EVen cracked these cables are worlds better than the overly resistive (friction) MP cables I was sent by Sudco.

    Carb is a tight fit, but not a problem. The accelerato pump chamber is close to the header but again not a problem. Install carb on slight angle to clear top frame tubes and header on bottom.

    Hope that helps, Esteban

    (Party time real soon)
    #7
  8. ErrinV

    ErrinV D Boon!

    Joined:
    Aug 24, 2003
    Oddometer:
    2,292
    Location:
    Alhambra, CA
    Mine has the FCR 39. It was on the bike when I got it though so I don't know what the difference is. I understand it's the way to go, but I've never ridden another 640 so I wouldn't be able to you what kind of difference it makes. This bike does haul ass though! Here's the link for the original ad that may be of some help.

    Good luck,

    Errin
    #8
  9. AndyB

    AndyB Lonely Traveler

    Joined:
    Dec 12, 2004
    Oddometer:
    173
    Location:
    WestbyGodVirgina
    Hey Thanks to All for the replies, Very much appreciated. be making a call to Sudco on monday. still looking for some jetting suggestions for my altitude 500-4500' asl. Again Thanks for the info guys and will post with my results .....,AndyB
    #9
  10. Nom de Guerre

    Nom de Guerre Long timer

    Joined:
    Nov 15, 2004
    Oddometer:
    2,034
    Location:
    Pasadena, CA
    Let us know what the cost of the setup is after you speak with Sudco. I'm pretty happy with the stock BST, but you never know... :ear
    #10
  11. ktmnate

    ktmnate Long timer

    Joined:
    May 7, 2003
    Oddometer:
    3,088
    Location:
    Somewhere
    ErrinV,
    I didn't know you bought Vincent's 640. That's a nice bike. That bike also had the power now insert in the intake. He said it made a big difference.


    Nate
    #11
  12. ErrinV

    ErrinV D Boon!

    Joined:
    Aug 24, 2003
    Oddometer:
    2,292
    Location:
    Alhambra, CA

    Hi Nate :wave.

    Thanks it is a nice bike. A little bit more scuffed since I bought it. :dunno It does have the intake, but I've never ridden another 640 so I can't really compare.

    You're coming down for the X2 ride right? Wish I could make it, but the wifey has plans for that day.

    Errin
    #12
  13. overlandr

    overlandr Dystopist

    Joined:
    Nov 30, 2003
    Oddometer:
    5,929
    Location:
    Sydney
    Read a posting on ktmtalk advising to use identical jets etc between the 41 and 39. PM'd Vrago about this thread - maybe we'll get to find out some hard data!
    #13
  14. ktmnate

    ktmnate Long timer

    Joined:
    May 7, 2003
    Oddometer:
    3,088
    Location:
    Somewhere
    Yep, I'm comming down for X2. I was at the first LC4 tech day when Vincent installed the power now. He said it made such a big difference that he was glad he put it in. I think Passmore got one as well. It's somehting I have been considering. I will have to wait untill I get my '06 and start building.


    Nate
    #14
  15. Tim

    Tim Long timer

    Joined:
    Dec 9, 2002
    Oddometer:
    2,365
    Location:
    Guernsey, Channel Islands, UK
    I fitted a FCR41 to my bike. I used re-routed stock cables on mine and I have a Sommer under-bar mounting for my Scotts damper. Also reverted to the stock carb to head and carb to air-box rubbers after getting and using the KTM items from a 660 smc which comes with the FCR as OE, I found that they were much thinner rubber and split quickly. I am using jets from James Dean,
    Pilot jet = 50,
    Pilot air screw = 1 turn out (same as 100 pilot air jet),
    Blue needle with clip on 4,
    Fuel screw 1 1/2 turns out,
    Main jet 172

    Bike is jetted for sea-level, with KTM air-box door and full Akrapovic with baffle fitted.
    #15
  16. vrago

    vrago Plays with dirt

    Joined:
    Mar 31, 2002
    Oddometer:
    899
    Location:
    Occidental, CA - Sonoma County
    Power now vane did not impact jetting & vice versa.

    I do not recall exact jetting. I think I gave the jetting data to Errin with the HP maps from Factory. They were good, if a bit expensive. Factory did build a jet kit for the FCR39 on an LC4 (basically they stored the data in thier database and will build one when ordered) so you could go that route.

    Errin, look at the graphs I gave you, all the jetting data is there.

    I never did get the Boyessen pumper cover on that carb, but have done so on my 450 EXC and am super pleased.

    I have not yet added the power now to the 450 exc, but will do so.
    #16
  17. ErrinV

    ErrinV D Boon!

    Joined:
    Aug 24, 2003
    Oddometer:
    2,292
    Location:
    Alhambra, CA


    Hi Vincent,


    I'll pull those out when I get home and post the info.

    Vincent--check your pms. I have a question about trials bikes.

    Errin
    #17
  18. nosedive

    nosedive Been here awhile

    Joined:
    Sep 6, 2005
    Oddometer:
    113
    Location:
    Thailand
    I installed a FCR39 from a KTM 450MXC last Friday. Works like a champ, clutchless wheelies in first gear, no problem. Stock 450 MXC jetting but I richened up the needle a bit turned the idle up a tad. I rode 500 street and 75 dirt on Saturday and Sunday, gas mileage is the same as with the BST-40.

    By the way, the dirt portion was the Cal Poly Penguins Hi Mountain 250 Dual Sport in San Luis Obispo. Excellent event for adventure bikes.
    #18
  19. AndyB

    AndyB Lonely Traveler

    Joined:
    Dec 12, 2004
    Oddometer:
    173
    Location:
    WestbyGodVirgina
    installed a FCR39 from a KTM 450MXC last Friday. Works like a champ, clutchless wheelies in first gear, no problem. Stock 450 MXC jetting but I richened up the needle a bit turned the idle up a tad. I rode 500 street and 75 dirt on Saturday and Sunday, gas mileage is the same as with the BST-40.


    THANKS Guys !!! ( to EVREYONE who has offered set up help)REALLY Appreceiate! the beta on carb set up. Now I gotta get the dang thing ordered. Curious as to your referencto "James Dean" Jets and needle? you speak of KTim. are these something sudco will supply or do i need to get them from some other, James Dean, source? ...Wow! many thanks again guys, will report as soon as mod as been aclompished.....AndyB
    #19
  20. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    http://jdjetting.server304.com/

    How much $US for the FCR ? from Sudco or elsewhere ?
    #20