640s 127,000 service and again at 212,000

Discussion in 'Thumpers' started by gunnerbuck, Oct 29, 2010.

  1. dnrobertson

    dnrobertson Big Bike, Slow Rider

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    I have done a similar thing with my Mosko R80 (re top plate). Never found the need to reverse them (which I can't do anyway as mine are Version 1), but I don't ride with a pillion, so I have removed the pillion pegs and use the top bolt of the pillion peg mounts as a mounting point for the leg strap.

    To protect those straps (through the plate), I run them inside bicycle inner tube as I found that regardless of the radius I put on the slots there was still some major wear.
  2. gunnerbuck

    gunnerbuck Island Hopper

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    I like to keep them away from the passenger area, this definitely creates some extra hassle to make them stable to the racks..
  3. GS2Trout

    GS2Trout Adventurer

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    Gunner,

    Great looking bike!

    Could you share details on painting and decaling the tank? I might be faced with that task.

    Even though I love the orange of the newer 640 Adventure, I find your gray/black color scheme to be the most appealing.......

    Thanks,
    Bill
  4. gunnerbuck

    gunnerbuck Island Hopper

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    Hi Bill,
    The silver and black is the original color scheme of the bike... I only painted the wings of the tank and left the decals as they were by taping them over before painting... I took a side panel into an automotive shop and they were able to color match and supply me with some spray cans of paint.. I do a touch up once in while to cover up scratches + wear spots from my tank bag and tank panniers..
  5. timeOday

    timeOday Long timer

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    So have you tried the new EXC forks offroad yet?

    (If they're a big improvement, part of me doesn't want to know...)
  6. gunnerbuck

    gunnerbuck Island Hopper

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    I haven't had a chance to get out for a long ride yet, but in the bit of riding I have done the forks don't feel that much different than the old units..

    The old units had the triple bushings which sometimes caused complaints about stiction, I found they would stick a bit when the bushings were new after a rebuild but after some wear in time it was no bother...
  7. bikemoto

    bikemoto Tyre critic

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    My EXC has the triple bushings. My suspension tuner moves the top bushing to the bottom, simply by installing the spacer tube first, then the top bushing, then the bottom bushing. Says it makes them more like a normal twin bushing fork.

    It's probably more economic and a better result to simply revalve the 640 forks, than source EXC forks... which will still need revalving. If you can get 'em real cheap in good condition, might be worth it. But I suppose it depends on what forks are on your 640 in the first place; mine are the same.
  8. gunnerbuck

    gunnerbuck Island Hopper

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    Mosko Mounting..
    [​IMG]
    Cut a piece of rubberized mat for a protector.
    [​IMG]
    And it fits like so..
    [​IMG]
    Because the bottom straps were below the frames and did not work to tie in, I had to come up with a new plan.. Instead of cutting strap holes in the forward edge of the bags I decided to use fender washers and 1 bolt per side to stop the bags from sliding fore and aft..
    [​IMG]
    The one hole in each side was easy to do. I used a hole punch to make a small hole and then pushed a red hot screwdriver through to cauterize the fabric..
    [​IMG]
    Once the bolts were tightened the bags became very solid to the bike
    [​IMG]
    The should protect the base of the bags from getting rubbed up..
    [​IMG]
    My 2 gas bottle pouches will clip nicely the the rear attachment webbing panels..
    [​IMG]
    Finished now, just need some camping weather..
    [​IMG]

    [​IMG]
    They mount pretty cleanly when looking from the back view.. They feel as sturdy on the bike as my Mosko BC 35s..
    Harder1 likes this.
  9. sprouty115

    sprouty115 Long timer

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    Tidy setup.
  10. gunnerbuck

    gunnerbuck Island Hopper

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    Yeh, if they move around too much I'll just hook a rock strap from the pannier frame loops over the bag on each side..
  11. gunnerbuck

    gunnerbuck Island Hopper

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    [​IMG]

    I have put over 2000 km on the build so far and the bike is running well and feeling broke in..
    bikemoto, Bobski911, wrya1 and 2 others like this.
  12. Bobski911

    Bobski911 advn00b

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    Wow, good for you man! What do you have for kms on your second bike?
    Your paint job looks good too! ;-)
  13. gunnerbuck

    gunnerbuck Island Hopper

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    I put 17,000 KMs on my other bike last year ...
  14. gunnerbuck

    gunnerbuck Island Hopper

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    So ends the main bikes journeys, at 219,000 KM... The evening before this years big ride I was doing the final inspection and found something that gave me cause for concern...
    [​IMG]
    These photos show a crack on one side of the shock tower top mounting point..
    [​IMG]
    Being chromoly steel, it is very strong, but also prone to fatigue stress cracking after years of vibrations.. It should be heat treated for welding, but in this case it is the second weld requirement, {the first was the subframe mounting thread insert that I tacked back in place} on this frame... So instead of welding it back together I am going to condemn the frame altogether and tear down the bike spreading the best parts between my 2 other 640 Adventures..
    [​IMG]
    About a month and a half back I purchased a 3rd 640 A for parts, and now I'll piece most of the best parts from my main bike onto this platform...
    [​IMG]
    I ended up taking my Ebay/Fleamarket project bike on this years adventure with very short notice, it had been sitting for almost a year since last ridden and all I did was change the oil and swap out mufflers for the trip, it performed flawlessly on this trip..
    Here is a link to that ride: http://advrider.com/index.php?threads/10-days-to-play-late-summer-17.1256499/
  15. lc4esupermoto

    lc4esupermoto Adventurer

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    This has been a really interesting thread to follow. Great stuff:beer
  16. GodSilla

    GodSilla I did that.

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    I too bought a spare bike (another 2003) that has become my main ride. :lol2

    This has been a great thread eh.

    It could be a way to honour this wonderful motorcycle by following the fortunes of those other bikes that receive the donor transplants.:wink:



    PS Is it just me :hide , or are a lot of the images unavailable? (Post 488 for instance). Is this bad photobucket ju-ju?
  17. ynnck

    ynnck Adventurer

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    Belgium
    Ah man, that's a shame! At 219,000km the bike is/was most probably the highest mileage 640A.

    I'm also unable to see the images of older posts, pity as I wanted to see how you installed the Mosko Moto Reckless 80.