'99 KTM 640Adventure-R rebuild time

Discussion in 'Thumpers' started by Low594, Mar 22, 2010.

  1. Low594

    Low594 Adventuring Creep

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    I dont remember which inmate deserves credit for it, but its an awesome idea! Much better than the TT light guards and so cheap and easy! Free to me!

    - (2) standard size computer fan grills
    - spray paint of your choice
    - (8) 1/8" x 1/2" pop rivets
    - pop rivet gun/tool
    - drill motor
    - 1/8" drill bit

    [​IMG]
  2. Seikkailu_R

    Seikkailu_R Been here awhile

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    One small question...
    Is there any other way to clean lights with grills than hose...

    [​IMG]

    Why not bolt small rubber isolators to holes, and attach grill to these with wing nuts?
  3. Low594

    Low594 Adventuring Creep

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    I figured a thick bristle brush should clean well enough. But I did notice that the fairing is quite thick and very tuff in those areas. So I've been thinking i would drill the holes out and tap them to accept bolts. I'm also going to bend the ears and use nylon spacers to get the grills to match the angle of the lens, which should have them looking even better!
  4. Low594

    Low594 Adventuring Creep

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    I had a pair of inmate Sanjoh's lights mounted in the front turnsignal holes, but wanted my turnsignals back. So I fabricated actual mounts that bolted in with the Roadbook mount. Since I only had aluminum, I'm planning to redo these so, but I know know the location works well! I just scored some 16g stainless angle to make new brackets!
    [​IMG]
  5. Droptarotter

    Droptarotter Long timer

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    Low594;
    Great thread.......I wish I knew you were looking for hardbags when I bought your dirtbags pannier mounts........I have some KTM racks and Happy Trails aluminum bags........damn.
    I really like the idea of the computer fan guards...........reminds me of using a computer fan to keep the original RFS motors cool.

    Cheers
  6. Low594

    Low594 Adventuring Creep

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    Yea, I would have loved to gotten those from you, but Stomp had put them aside for me when I bought the bike. I really like them, except they are wide for daily use in town and the brackets almost line up smoothly. They make commuting really easy, tool bag, hardhat and lunch all drop right in!

    How did the computer fans work, I always wondered. Figured they wouldn't flow enough air to be effective, but I guess most anything would be an improvement, right?
  7. Droptarotter

    Droptarotter Long timer

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    I honestly don't remember if the computer fans worked for the guys.
    My bike never seemed to overheat,so I never installed one........I guess living in The Great White North has something to do with it, or the JD jet kit to get it to fuel properly.

    The pannier mounts have arrived, but I have not had a chance to pick them up.

    Friday was the first time I got to ride the 640........it didn't feel too bad.........had a bit of a weave/wobble/oscillation over 120kmh, but that could have been the old tires. I will recheck the wheel alignment to be sure.
    The mentioned vibrations did not bother me.......and I never got a chance to get it off of the streets and into the bush........so it was not ridden in it's element.

    I also noticed that my battery tender is blinking red after about 12 hours.........maybe the battery is toast also..........damn.......more money.

    Cheers
  8. Low594

    Low594 Adventuring Creep

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    Hmm! I seem to forget to update this!

    In the last year, the bikes seen some miles, not sure how many due to the dying IMO, guesstimate is 3k miles. I've had to replace the head gasket. I'm working on a better solution for an enrichner cable, using one from a HD Kiehin CV carb, works well so far, just not positive it completely closes. Also, swapped out the popsicle mirrors for more modern KTM mirrors. Sold the ADVMonster LED 1500lumen flood for ADVMonsters LED 3600lumen flood! Replacing the connectors for the regulator/stator has remedied the poor charging issue! I ditched the stock taillight and put one of Acerbis' LED lights and inner fenders. At the same time, I painted the worn out side plastics and rear fender, satin black. So there is no more Orange, other than the Orange Crush shock cover and the 2 orange ASI silicone hoses. I'm kind of torn on this, some days I like the orange, other days the black is good. I also got a nice Ipod Nano mount, mounted to the dash bar, with volume control. I also ditched the BMWstyle cigar power port and replaced it with one of 3BR Powersports USB powerports!

    Currently, the forks are headed to my buddys shop in San Jose, DJ Cycles. DJ will be replacing the seals and widening the footpegs. I also tore the SXC muffler apart, of which the packing had greatly deteriorated. I drilled out the rivets, taped the end caps and put 1/4"-28x1/2" allen cap screws in. Also using the good FMF pink packing. Should sound alot better when I am done!

    I've got alot more plans in action, but we'll see how my momentum holds up. Such as TrailTech Vapor Stealth, Heidenau K60Scout tires. Looks like I need to take some new pics, also!
  9. biensur22

    biensur22 Been here awhile

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    Indeed i think some pics are in order. Why are you widening the footpegs rather than just replacing the L/S peg hanger and mounting up anything you wanted? I can't seem to find it from the thread, but which carb are you using that you're having trouble with the choke cable?

    Edit: And what kickstand is that!? The my stock stand is about to give out from abuse.
  10. Low594

    Low594 Adventuring Creep

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    Just got my footpegs beefed up! Much nicer now!
    [​IMG]
    [​IMG]
  11. biensur22

    biensur22 Been here awhile

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    Holy hell! I retract my previous question, those are awesome.
  12. Low594

    Low594 Adventuring Creep

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    Does it make sense now? Aftermarkets cost $100 and up! These cost me nothing! Cutting up the frame would be too far with all the options out there!

    Currently, I am using the stock Mikuni BST40. The issue I have had is that I rarely need the choke and the cable gets bound in the steering and sometimes comes on slightly. I also want to simplify the controls/handlebars. The shorter cable seems to be working well, but I did have to modify the knob so that there was slack in it. I am considering a conversion to a FCR41, my brother has an extra from his XR675L/SM project!

    The kickstand is the SW-Motech, also referred to as the Shin Death Dealer! As soon as you move the bike off the stand it retracts, due to Euro Vehicular Code!
  13. Low594

    Low594 Adventuring Creep

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    I've long neglected updating my progress, so here goes!
    [​IMG]
    Mirrors & handguards of newer KTM
    ADVMonster M60(3600lumen) LED Flood, ADVMonster 10w(450lumen) LED Spot
    Hella Supertone horns, Computer fan grill headlight protectors, Lockhart/Phillips billet clear turn signals
    KTM fender (part #5030801030030), Seal Savers (All Balls seals and wipers inside)
    [​IMG]
    Almost new condition seat, side panels and rear fender painted satin black(orange was worn out and looking bad!) footpegs widened by DJ Cycles, MotoSport hardbox pannier racks, ProMotoBillet tail shelf, SXC muffler (FMF repack and allen screw conversion), Touratech skidplate, SW-Motech sidestand w/extension, custom Orange Crush shock res cover
    [​IMG]
    Acerbis LED tailight (part #210470001), Lockhart/Phillips billet clear turn signals
    [​IMG]
    Left to Right: toggle for ADVMonster M60 flood LED, Magellan Triton400 (hiking/offroad GPSr), Ipod Nano, Magellan Maestro (road nav GPSr)
    Found to the left of the Scotts Dampner: volume control for Ipod

    Parts not seen:
    -SXC enclosed chainguide
    -RLR Coolant Recovery Tank
    -pre-muffler delete S-pipe
    -KTM airbox side cover
    -KTM updated radiator cap
    -3BR Powersports USB powerport
    -Stenhouse fuel mixture screw
    -oversized Tool Tube (holds tools and stove fuel!)
    -ASI silicone radiator hose (found on Ebay; despite coming from China they were very responsive!)

    Soon to be done:
    -620Rallye rear disc guard
    -Trailtech Vapor Stealth
    -Stenhouse Sub-Dampner mount
    -2009 exc throttle tube/housing/cables
    -950 right control pod
    -swap M60 light into Hi Beam location
    -upgrade Low Beam to Bi-Zenon Projector
    -rear LED strips to add running ckt, sequential turn signal & brake strobe
    -Passmore's centerstand EZ-Up mod
    -Emig Racing 1-1/8" lowering links
  14. Droptarotter

    Droptarotter Long timer

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    Low......

    Very nice........except for the color.........I hate blue!!

    The Stenhouse mount is very nice.........give Loadedagain a call for the rise you require.
    I was fortunate that Colin lives/works close by and was able to deliver what I needed for the Scott's damper install.
    Look into the Scott''s rear disc guard as they are very nice!

    I can also supply you with a tool tube if you need one???

    Hope you are well!

    Cheers
  15. bmwktmbill

    bmwktmbill Traveler

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    Low,
    That's a nice motorcycle, very distinctive but very functional.
    Nice job!!!
    bill
  16. Low594

    Low594 Adventuring Creep

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    Thank you! I like the blue, especially since there were so few! I go back and forth on my like of Orange. i got the Tool Tube covered, originally bought 5 and now i only have the modded one left!
    Thanks! Looking forward to another nice long trip!
  17. bisbonian

    bisbonian Long timer

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    Where did you come up with this?

    I've had one on order from KTM for the past 5 weeks and was just told that they have been discontinued.
  18. Low594

    Low594 Adventuring Creep

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    At the time, I didn't know that you could get one from another KTM model, so I took it down to an exhaust shop and had the center replaced with the straight pipe. Its a difficult job, the pipe has to be squished into an oval shape before welding, so its not a job for the average shop.
  19. Low594

    Low594 Adventuring Creep

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    Well, over the last week I got a few miles of riding in, nothing too fun, just around town. But also got a bunch of work done, mostly cleaning the pigsty know as my workshop! But I figured out my fan hasnt been working, altho it still has been fine in the cooling department. The fuse was blown, after changing it, the fan comes on when I short the switch, but hasnt turned on while riding, so that might be bad! I also, pulled the fairing and tank off and started installing the newish throttle assembly from a 2008 250XCF. It came from ebay with a G2 throttle sleeve and K100 cam. I also put new cables on it, lubed the cables and greased the hell out of it all! It's nice! It also got a used 950 right side control pod. The reason I changed them is that the earlier 640A have the throttle assembly and right controls as 1 unit, so it's not possible to adjust the cable housing and the starter button independently. Still left to be done there is to swap the wiring over, looks to be plug and play, move the grip heater over, then put the grip, handguard and barend weight all back together.

    I'm going to see if I can use an old set of knockoff CRG Barend Mirrors, except they will be inboard of the control pods on either side. That should clean up the bars quite a bit!
  20. bmwktmbill

    bmwktmbill Traveler

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