Just another ktm 640 adventure rebuild

Discussion in 'Thumpers' started by sergiu_sergiu, Oct 18, 2012.

  1. mtbdemon

    mtbdemon Long timer

    Joined:
    Nov 16, 2007
    Oddometer:
    1,106
    Location:
    Beaverton Oregon
    Double ditto!! Would love to learn more about the sticker set....
    #21
  2. bmwktmbill

    bmwktmbill Traveler

    Joined:
    Jul 16, 2005
    Oddometer:
    5,658
    Location:
    Traveler
    Seals.

    It's the cost of oil vs the cost of seals, old seals make good spares if you are going traveling esp. outside the USA.
    bill
    #22
  3. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    All the mechanical parts arrived today (all chassy seals and bearings + weal seals + bearings), got the new tires (went for the conti tkc 80) mounted them, and planning to do some more work today.
    This is where I’m at right now.


    [​IMG]
    beautiful new (8000 km) high flow engine :evil
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    #23
  4. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    I’m also planning to do a valve inspection using the guide on the site, actually all the guides I used are found in the lc4 thread index – very useful things over there :clap
    Here is a little improvement of the center stand:
    [​IMG]
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]-->[FONT=&quot]I have a problem with the body and the painter has not been able to deliver it yet. He promised next week but then again he’s been doing that for three weeks. Those of you whom are interested in the stickers please be patient.[/FONT]

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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> So, stay tuned for updates [FONT=&quot][/FONT]
    #24
  5. biensur22

    biensur22 litigious poster

    Joined:
    Oct 26, 2011
    Oddometer:
    183
    Location:
    Denver, CO
    Make sure you loctite that center stand back on. I lost mine on a ride this weekend -- thought a set of nylocks would be sufficient.
    #25
  6. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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Priority="67" SemiHidden="false" UnhideWhenUsed="false" Name="Medium Grid 1 Accent 6"/> <w:LsdException Locked="false" Priority="68" SemiHidden="false" UnhideWhenUsed="false" Name="Medium Grid 2 Accent 6"/> <w:LsdException Locked="false" Priority="69" SemiHidden="false" UnhideWhenUsed="false" Name="Medium Grid 3 Accent 6"/> <w:LsdException Locked="false" Priority="70" SemiHidden="false" UnhideWhenUsed="false" Name="Dark List Accent 6"/> <w:LsdException Locked="false" Priority="71" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful Shading Accent 6"/> <w:LsdException Locked="false" Priority="72" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful List Accent 6"/> <w:LsdException Locked="false" Priority="73" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful Grid Accent 6"/> <w:LsdException Locked="false" Priority="19" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Subtle Emphasis"/> <w:LsdException Locked="false" Priority="21" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Intense Emphasis"/> <w:LsdException Locked="false" Priority="31" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Subtle Reference"/> <w:LsdException Locked="false" Priority="32" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Intense Reference"/> <w:LsdException Locked="false" Priority="33" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Book Title"/> <w:LsdException Locked="false" Priority="37" Name="Bibliography"/> <w:LsdException Locked="false" Priority="39" QFormat="true" Name="TOC Heading"/> </w:LatentStyles> </xml><![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Does anyone have a service manual for the 2001 adventure?
    #26
  7. bmwktmbill

    bmwktmbill Traveler

    Joined:
    Jul 16, 2005
    Oddometer:
    5,658
    Location:
    Traveler
    It's here....


    http://www.horizonsunlimited.com/hubb/ktm-tech/ktm-lc4-workshop-manual-98-a-35025


    bill
    #27
  8. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    #28
  9. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Hi guys,
    New question: can I change the hydraulic clutch line for a brake line? The problem is that with the new bar risers, the existing clutch line is to short, the brake line (that I have laying around) seems to have the same couplings, but the line it’s self, is thicker…
    On Monday promise new picks with the progress, it should be near finish by then :D
    #29
  10. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Hi all,

    So work continues and I have good progress. Finally the parts came back from paint. The guy that made the stickers will not give up the corel version of the stickers, but this is he’s email (with he’s approval) andrei.ovedenie@gmail.com. Contact him regarding the stickers if you are interested. They are printed stickers that stick to the painted parts, I cannot give you a full review, as I just got them, but I can tell you far sure that a very important part is the way they are applied on the parts. I don’t expect them to last forever, but they look nice and for me it was worth it.
    :evil

    [​IMG]
    #30
  11. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Here are some improvements and improvisations I made or a had to make:

    As I changed the stock muffler, had one made exactly the same but hole inside and with a removable cap – this I’m going to use as a tool box

    [​IMG]


    and this is what it looks like closed


    [​IMG]


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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]-->
    The bar risers are perfect for me, but it was a big hassle to install due to the steering stabilizer. Because I raised the bars I had to change the clutch line, so a used an old brake line I had around



    [​IMG]
    #31
  12. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    Did a reinforcement for these mounts as they both broke off.
    [​IMG]
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    This is the front assembly that holds the homemade rally fairing.
    [​IMG]
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]-->
    As I used the duke electrics to fit the new engine, in the battery compartment did not accommodate the electric pieces so I had to improvise this mount that will sit on top of the battery an also hold the battery down. I going to use zip-ties to hold it down.


    [​IMG]
    #32
  13. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Lots of things to do still and little time, but I’m getting there.
    This is the tank on the bike:
    [​IMG]
    #33
  14. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
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font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> Here are some questions, so some answers would be really helpful :
    The red wire on the fuse box lookalike :shog connects to the battery and the starter motor wire connects on the fuse box lookalike?
    For those of you with the trail tech vapor I mounted the rpm sensor on the blue and white wire coming out of the coil – will it work?
    #34
  15. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    tried to start the bike this weekend, and before the battery died (about 5 min) all i got wore some loud misfires, is this normal? any tips?
    #35
  16. Droptarotter

    Droptarotter Long timer

    Joined:
    Jul 11, 2007
    Oddometer:
    1,589
    Location:
    Cloverdale,BC
    Not really normal, but if your battery died it might not have had enough voltage to fire the beast.
    Maybe time for a new battery and try again.

    Some nice work there sergiu!
    #36
  17. ericGSsti

    ericGSsti Been here awhile

    Joined:
    Oct 9, 2009
    Oddometer:
    791
    Location:
    Dublin, Ireland
    Look very well. I have a thing for repsol rally replicas.

    I eventually go the repsol route myself.

    Keep up the good work man. :clap
    #37
  18. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    well my friends, the bike has been done for about two weeks now. things wore very bussy at work, but finaly i got around to taking some pictures :evil
    [​IMG]

    [​IMG]

    [​IMG]
    #38
  19. sergiu_sergiu

    sergiu_sergiu Adventurer

    Joined:
    Oct 20, 2011
    Oddometer:
    25
    Location:
    Bucharest
    [​IMG]some more pictures:

    [​IMG]





    [​IMG]

    [​IMG]
    #39
  20. ericGSsti

    ericGSsti Been here awhile

    Joined:
    Oct 9, 2009
    Oddometer:
    791
    Location:
    Dublin, Ireland
    Very, very nice.

    Looks really good. :clap

    Any idea where the front fairing came from?
    #40