KTM 640 Adventure Rally / Adventure Bike Build

Discussion in 'Thumpers' started by jrozar, May 20, 2013.

  1. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    I was in the quest to build a solid middle weight adventure bike but also capable of running a few rally's in Baja this coming year...

    I was able to find a 2006 Adventure with 6K miles and in excellent condition. It was used to attack the urban jungle to work and back by the previous owner.

    As soon as i got it I took it down for a carb cleaning and rebuild and a good going through by Ken at MTC.

    So far here is the progress -

    Side Shot-
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    Scotts Stabilzer and Road Map Holder installed- I am changing the mounting of the Scotts to below the bar in changing the top triple clamp. The bars are a little low for a standing position.

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    Happy Trails pannier system installed, one of my favorite features of this is that it provides well needed crash protection and triangulates the rear of the bike.

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    Factory Supertrap exhaust, it will be soon changed out for am FMF Q4, which is sitting in the garage ready to go on.

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    CNC cut radiator guards

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    Touatech rear luggage rack-

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    Scott's Rear Disk Guard

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    Touratech Skid Plate

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    Then I took the Bike down to M Power Rally Bikes in Boulder City Nevada and they started working their magic taking it all the way down and have now started putting it back together.

    M Power built this 570 Husaberg this year for a friend of mine...

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    Going back together....all engine & cooling system work completed

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    Stock lights are getting ready to be pulled and replaced with Dual Vision X Optimus

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    New Silicone hoses, higher CFM fan and reworked radiator for better cooling...

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    New Scotts Triple Clamp, Underbar Stabilzer Mount and Bar Riser....

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    New Pirelli Rally Scorpions....

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    FMF Q4 installed...replaced the factory Supertrap...

    In with the new

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    Out with the Old

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    CJ Designs KTM Foot Peg Extension – LONG

    http://www.cjdesignsllc.com/products/ktm-long-foot-peg-extension

    I found these and they bolt to the factory KTM pegs and come in standard or long.

    They also make them in a weld on version.

    We went with the long so that it will allow me put all my weight on the very outside for better traction in corners.

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    #1
  2. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    New front fender bling....

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    Touratech Chain Guard

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    Better Shot of the Scotts triple Clamp and Bar risers for Under Bar Scotts Stabilizer Mount

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    BRP Low Resistance Chain Guide (This is made for the Husaberg but fits the 640, ( if you order one get unit for a '05-08 Husaberg its a perfect fit! )

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    Bullet Proof Designs Radiator Guards...
    https://www.bulletproofdesigns.com/products/type/radiator-guards.html

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    M Power Shock Installed....

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    What long legs you have.......

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    Bolt Axle Adjustement Blocks....

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    Rear Swing Arm with the bling! Chain Guide, axle block, chain guard, new chain.

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    Hyde Racing ktm Frame Guards

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    Touratech KTM Front Sproket guard intergrated with the factory plastic cover.

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    New Chain installed & safety wired clip!

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    Hyde Frame Guards trimmed & Installed

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    Engine looking good...

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    Custom Tuned Ricor Vibranators installed in the bars!

    http://www.vibranator.com

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    Seat Concept Seat Installed, for the long days in the saddle....

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    Fitting the tank to measure for crash bars and light mounts

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    Quick side shot before it comes back apart...

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    #2
  3. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    Findley Customs Las Vegas did the paint match for the front rally fender, the stock one had some abuse and we also did a 3m clear guard!

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    Chris at M Power made an adjustment bracket that can be used to raise or lower the fairing to match the tire.

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    Chris had an extended wrap over brake line with the Orange Bling made...This line goes over the rally fairing to tie in both calipers.
    Waiting for the install picture but you get the idea...it's long and skinny

    This is the picture he sent me....:huh

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    BajaDad came to the rescue with a 640 rally fairing for the build it was off his 2012 Mexican 1000 bike....

    Tribute to him in the first pic....

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    #3
  4. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    My Rally Raid Engineering Tank Guards arrived from the land down under...Very nice quality work!

    www.rallyraid.weebly.com

    The plan is to have the wrap go over the guards but have areas cut out so the CF comes through..

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    Parts back from AR Iron who did an excellent job with powder coating! These guys are A+ in my book...very reasonable with prices

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    Crash bars were back from fab, these are Holans and I found used and abused so had to have them reshaped ......also added two light tabs and had them powder coated at the same time. they will be receiving a set of Baja Designs Adveture Squadrons....

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    Found another hard to find discontinued part...this is the factory KTM side panel that opens the air box.... Nice extra farkle...

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    But the the best addition to the build will be adding this last....

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    #4
  5. biensur22

    biensur22 Been here awhile

    Joined:
    Oct 26, 2011
    Oddometer:
    179
    Location:
    San Diego, CA
    Awesome build. Nicely done.
    #5
  6. betitou

    betitou Thumperized!

    Joined:
    Feb 15, 2012
    Oddometer:
    101
    Location:
    Spain
    Holy shit! This is bikers' hard p0rn!!!
    #6
  7. Motorfiets

    Motorfiets Long timer

    Joined:
    Oct 1, 2007
    Oddometer:
    2,997
    Location:
    North of Jack Daniel's, South of Country Music
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    :drif
    #7
  8. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    You mean the one next to mine? :evil Im hoping some of the blue rubs off on my Orange...I did put a blue oil filler cap on the 640..

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    #8
  9. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    Few more things added today...as the new clutch and high output stator were going in...

    Carbon fiber just makes anything look better...I mean provides excellent protection...

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    Scotts Installed...

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    Planning to order some Black Zeta handguards with integrated blinkers....when I get off adv this evening...
    #9
  10. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    Thank you but Les and the guys at M Power do all the work...those guys are good...they took it to the next level....and their suspension is the best KTM suspension around...

    #10
  11. Kawidad

    Kawidad Long timer

    Joined:
    Jul 9, 2005
    Oddometer:
    5,120
    Location:
    Central Coast, Cal
    Nice!!!!! :clap

    With that open airbox side panel, make sure you put a filter skin on the filter. It makes life much easier.:deal
    #11
  12. Yooper_Bob

    Yooper_Bob Long timer

    Joined:
    Aug 31, 2005
    Oddometer:
    2,919
    Location:
    Da UP, eh! (Marquette, MI)
    :drif:drif:drif:drif
    #12
  13. Droptarotter

    Droptarotter Long timer

    Joined:
    Jul 11, 2007
    Oddometer:
    1,317
    Location:
    Cloverdale
    That looks great.................hey, why did you choose the FMF exhaust over all the others?

    I need something with a spark arrestor.

    Cheers
    #13
  14. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    I have used the FMF Q4 on multiple bikes and have always been pleased with the lower DB sound it produces, its spark arrested and the price. The Akra titanium is nice but for the cost I couldnt justify it... plus if I am worried about weight I will start with losing it off me before the bike, cheaper to diet than buy lighter parts.

    Also, HP is not a factor for me with bikes it is a last at best objective, I go for the best suspension, bike protection and my gear first... I may have another new FMF Q4 in the box at the shop for a 640 shoot me a PM if your interested or my factory supertrap is here too.

    #14
  15. Droptarotter

    Droptarotter Long timer

    Joined:
    Jul 11, 2007
    Oddometer:
    1,317
    Location:
    Cloverdale
    Sent you a pm.........
    Cheers
    #15
  16. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    Yesterday I started thinking of a rear light solution...Ive been looking for an LED replacement assembly but havent been able to find one so this is the setup I decided to go with.

    Being a light person....and have a firm belief in being seen, I ordered the following for the rear lights...

    Dual Intensity 45 SMD Tower 1157 to replace the stock taillight bulb and and adding hyperlites dual 8 led running and brake lights

    http://www.superbrightleds.com/search/led-products/1157/

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    Then I will be adding the hyperlites kit in for additionla rear lighting.......

    www.hyperlites.com/stdsf.html


    The U32 kit, Standard Flashing program, with Running Lights. We use a microprocessor to *give you running lights at 30% intensity, and brake lights at 100%! The 16 LED design gives these lights twice the power of our 8 LED lights, at about 1/4 amp! All the electronics are cast in epoxy to make them Water Proof and Shock Resistant!
    #16
  17. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    Todays Progress....

    Zeta Hand Guards with integrated blinkers arrived... (yes there will be a little blue on this bike)

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    Sten House Racing Extended Axle Bolt

    http://stenhouseracing.com/shop/index.php?main_page=product_info&cPath=5_4&products_id=23


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    This product has been designed to replace our axle pull. On newer model KTM LC4 and LC8 bikes KTM has been kind enough to thread the axle tubes extra deep. They ship bike with a very short axle bolt though.

    Our extended bolt is installed in place of the factory part and allows the axle to be pushed out of the fork bosses. Give the bolt a bump with a mallet (or a log on the trail) and it is free of the clamps.

    Makes removing your front axle a little easier without adding a measurable amount of weight... plus! it's a flashy little piece of "billet" to make your bike cooler than the other guys.
    #17
  18. dnrobertson

    dnrobertson Big Bike, Slow Rider

    Joined:
    Jun 30, 2008
    Oddometer:
    860
    Location:
    Frankston, Australia
    My Stenhouse nut doesn't get the axle free of the clamps, so to make pulling your axle even easier (without adding weight), drill a hole in the other side and you can insert a screwwdriver or allen key into it once you have tapped the stenhouse nut to it's limit.

    Have you checked your raised guard for clearance at full suspension clearance? I destroyed my std guard some how when it was crushed at full compression.
    #18
  19. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    I measured out at full and I have about an inch left...so i should be good.
    #19
  20. jrozar

    jrozar Been here awhile

    Joined:
    Jul 5, 2007
    Oddometer:
    627
    Location:
    Vegas Baby!
    I've decided for the Happy Trails soft bags and I am having a plate made for the rack that will hold rotopax cans. I figure I can run a bag for tools, gear etc.on one side.. And have the rotopax for water and spare gas.

    I'm having extra rotopax plates water jetted out....so if anyone is interested let me know hey will fit the happy trails and Touratech racks. I will post pics of that next week.
    #20