Its winter.....Time to upgrade the Desert Camel

Discussion in 'Thumpers' started by Zerodog, Dec 15, 2007.

  1. Zerodog

    Zerodog Long timer

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    So over the past year or so I have been aquiring lots of parts for my 03' 640A. The bike has 22,000 miles on it now and needs some lovin.
    I have put off the projects for one reason or another. Going on trips not wanting to risk changing something, other projects, working on other guys bikes, sick of working on bikes..... But now it is time.

    Here is the list:
    • FCR 39 Carb
    • Leo Vince full TI exhaust system
    • Rebuild and Revalve rear shock, (New ideas for valving and new heavier 8.4 spiring.)
    • New 20mm offset Factory Connection triple clamps with rubber mounted bars. ( Hopefully get the front a little less biased and fix my twisted set I have now)
    • New head bearings
    • Change oil and try out some new Base Valve stacks in the forks.
    • New Cycra hand guards
    • New right front LED turn signal
    • Get LED turn signals blinking
    • Weld up Crack in subframe and check for more.
    • Add a support bracket on the right side under the plastic side panel for my Ortlieb saddlebags
    • Change oil
    • Check valves
    • Maybe new clutch? So I don't need to worry about it later this year.
    I have got my work cut out for me. But it has been a long time coming. I will take pictures as I go along.
    #1
  2. bmwktmbill

    bmwktmbill Traveler

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    Zerodog, don't neglect wheel, swing arm and pivot bearings if you haven't already done them?

    Last winter I filled the grooves out of my clutch basket.
    So far so good.
    Did we ever get to the bottom of if there is such a thing as rally springs for the clutch?

    When I looked I could never find a part number that was different on the rally bikes.
    b.
    #2
  3. KenR

    KenR Long timer

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    Sounds like a fun winter project. I really want to have a look at the Ti exhaust and I'm curious what you've come up with for that soft bag support - I've been pondering the same thing and have looked at the Dirt Bagz mount.
    #3
  4. Zerodog

    Zerodog Long timer

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    KenR you will have to come over sometime and check it out and have some beers.

    I just fit up the exhaust last night. It looks pretty sweet and fit on easy enough. The only down side to it over stock exhaust is I loose support on the left side panel. Now I need to work on support on both sides for my saddlebags.
    #4
  5. cbig

    cbig Rift- Raft, SCooter Trash

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    looks like you have quite a project! You're gonna love the FCR.

    chuck
    #5
  6. meat popsicle

    meat popsicle Ignostic

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    Hey ZD,

    Something like this perhaps?
    [​IMG]
    http://www.promotobillet.com/catalog/product_info.php/cPath/24_82/products_id/197

    I am tearing into my front and rear suspension. I also have an oil change and some other misc. maintenance repairs as well... I hope to send you my rear shock soon, MP
    #6
  7. Zerodog

    Zerodog Long timer

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    The Pro moto billet thing is cool but I don't like it for my setup. And I don't think it will work as good for offroading. Believe it or not I like the bags sitting on the passenger seat zone. They are lower and more central to the bike for a lower center of gravity. They also do not interfere with my back rack for if I choose to carry a ton of other crap on a trip. I don't want to get any more brackets that you can see. So fabricating a frame from .5" tubular steel that hides under my side covers is the way I will go.

    Check out the pipes.:tb

    This is totally mocked up just to see if they fit. And they seem to fit perfect.
    [​IMG]

    A little different shape then stock. Notice how flat and straight the lower pipe is.
    [​IMG]

    Pre-dented for the FCR carb to fit.....hopefully
    [​IMG]

    :super
    [​IMG]
    #7
  8. KenR

    KenR Long timer

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    Sweet pipe man!! Is the silencer a sparky? Wondering what it'll sound like.

    (Sorry about the phone tag the past two weeks. Been traveling for biz every week. I'll try you this weekend. We gotta plan some crazy expedition for Spring)
    #8
  9. Loadedagain

    Loadedagain making chips

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    sheet... looks like fun doode!
    #9
  10. Zerodog

    Zerodog Long timer

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    The pipe came with a loud and quite insert and a sparky screen. All easily changed out by removing the end cap.
    #10
  11. empedrado

    empedrado Been here awhile

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    You wouldn't be interested in selling your bottom triple clamp would you? That is unless it is severly twisted. I might be able to trade for some of my 640A parts if you want.
    #11
  12. Zerodog

    Zerodog Long timer

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    I wouldn't sell any parts that were twisted or bent. On top of being screwball it compromises the performance of the front end.
    #12
  13. Zerodog

    Zerodog Long timer

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    Well this weekend I decided to finish up part of the project. I have been so busy with other guys bikes I haven't worked on mine a whole lot. I had a small window of time and weather to get some stuff done and I skipped the BS non essentials and got it running.


    Holy fucking guacamole is it faster, punchier and more like a real 600+cc dirtbike. It feels twice as fast and I know it still isn't perfect with jetting. I did a wheelie today going over 30mph. No way in hell would the old setup do it. Not without some kind of hump, whoop or other help. I don't have 3rd gear wheelies down yet but with some more jetting love I am sure I can get there. I will post some pics of the pipes and the carb soon. I need to get them uploaded.

    So far:
    FCR 39
    Racing side cover screen
    Leo Vince System
    New rear shock valving and 8.4 shock spring

    I need to work on a few things with the exhaust. Another mounting point for the muffler would be nice. I don't think 1 is enough for 100s of miles of offroad ridng. I don't want to loose that baby on some dirt road somewhere. And I think I might need to weld 1 other spring mount to the muffler and header. It only has 1 and puts a weird torque on the pipe and it doesn't quite sit straight in the carbon mount. But another carbon mount could fix this too.

    And before I can even think of any real trips with saddle bags the support frames need to get built for under the # plate/ side covers to keep off the pipe.

    Still need to work out the front end twist I have going on. All of the clamps I have aquired will not work well for my bike so I need to toss them and keep my eye out for a new set of clamps and possibly some new forks. This is probably last for now. It all works pretty good now.
    #13
  14. borsiin

    borsiin Been here awhile

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    Clutch springs are harder for the Rally, not much but enough for curing all problems qith slipping. Avaliable from KTM-Sommer in europe.
    #14
  15. humdinger

    humdinger bp

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    The Leo system looks very well made Zerodog! I found the Akro a little 'tight' in areas. The mounting of the muffler is also a little vulnerable like you have stated. The carbon mount loosens with every 'ruggered' mile and creates a bit of play. A second mount is a good idea.
    Starter motor housing on my 05 has about 1mm of clearance from the Akro header and the outer fuel pump housing of the FCR (mines a 41 mx) is a little closer than desired. I had a fellow member try my old header (original) on his '98-620 LC4 with the FCR (non mx) and it fits with oodles of room. I think I might have got a P.O.E.T.S (piss off early, tomorrows saturday) pipe out of the Akro factory.

    [​IMG][/IMG]

    [​IMG][/IMG]





    Big difference with a decent pipe and the FCR isn't it!
    I'm about to put a 45 rear sprocket on mine as I could do with a tad more revs down low in the tight stuff.
    Still haven't got around to fitting those springs and valve shims.
    Gettin' mighty quick at changing diapers though :lol3
    #15