KTM 640 Adventure "windshield" removal

Discussion in 'Thumpers' started by Magile, Aug 14, 2006.

  1. Magile

    Magile "What exit?"

    Joined:
    Apr 11, 2005
    Oddometer:
    681
    Location:
    Exit 163, NJ
    I'm hauling a new-to-me 2003 640 Adventure in my Dodge van. Can someone suggest what tools I need to remove the plastic windshield?

    The van's openning is 49" high. The mirror's will have to be removed too.

    Thnx.
    Magile
    #1
  2. rogersboyz

    rogersboyz Adventurer

    Joined:
    Jul 5, 2005
    Oddometer:
    81
    Location:
    92604
    On my 2005 and my 2006 you need an 8mm socket for the two left and two right bolts in the sides of the main fairing, then the three screws around the top of the instrument panel must come off (don't lose the washers). CAREFULLY seperate the black top of the instrument panel from the lower fairing. There are rubber plugs that hold the pieces together, and the whole setyp is a bit delicate. The lower fiberglass fairing comes off forward, again CAREFULLY. The black top instrument panel stays on the bike.

    Good luck.

    Jeff Rogers
    Rogersboyz@aol.com
    #2
  3. creeper

    creeper Still alive...

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    I don't know what "rogersboyz" is smokin'... :dunno

    But to remove your fairing, all you do is remove all six 6mm bolts with a 8mm socket... then pull up the lower "ears" of the black inner instrument panel, which lifts the locking tabs out of the 4 rubber grommets in the fairing.
    At this point, there is nothing holding the fairing in place... you don't have to unbolt the instrument panel.

    Pull (flex) the two fairing rear sections outward a bit to clear the mounting bracket... and pull the fairing straight off toward you.

    Takes about 3 minutes tops... or less time than it took to write this.
    And nothing about a KTM 640A fairing is either "delicate"... or fiberglass.

    That's it,
    C
    #3
  4. rjf

    rjf SBS's #1 fan in January

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    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    Creeper speaketh thye trutheth :pope
    #4
  5. SamH

    SamH 90S on the bench

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    Oddometer:
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    Mine's got the old 2 piece fairing. Sounds like the only difference is that the old ones have cap nuts holding the instrument pannel in place instead of press lugs.


    If it's an old one, undo the 6 bolts and 3 nuts on the instrument pannel and pull the fairing up and towards you (standing at the front of the bike).

    Unplug the instrument panel quick connects and the indicators and you're done.
    #5
  6. Magile

    Magile "What exit?"

    Joined:
    Apr 11, 2005
    Oddometer:
    681
    Location:
    Exit 163, NJ
    Thanks C!

    I just started combing thru the LC4 index...whew! There's tons of info there.

    There are a few things I'll do before hitting the road & trail - replace the chain & sprockets if they're are original, inspect the valves, and do a fresh oil change, any other recommndations?

    Gracias,
    #6
  7. SamH

    SamH 90S on the bench

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    Tasmania, Australia
    Get it serviced by a reputable shop, unless you're a confidant home mechanic of course.
    #7
  8. creeper

    creeper Still alive...

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    Assuming (standard paranoia) the previous owner did nothing but maybe change the oil...

    • Service all the chassis bearings.(disassembly required)
    • Service the Pro Lever. (more disassembly required)
    • Battery condition and basic charging check.
    • Cable lubrication. (there are only three... and they all go to the carb)
    • Nuts and bolts check. (the two bolts that hold the header support bracket to the subframe above the upper chain roller in particular)
    • Air filter.
    I'll stop here to avoid a complete OCD caliber bike tear-down. :D

    C
    #8
  9. ChrisC

    ChrisC Amal sex?

    Joined:
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    Prescott, Arizona USA Earth
    Except I'll bet they've gone MIA, so tightening them will be problematic... :wink:
    #9
  10. creeper

    creeper Still alive...

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    And 6X12mm bolts are sooooooo hard to find. :evil
    #10
  11. 2 SPOT

    2 SPOT wannabe

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    knockin round the rim, AZ
    hey creep your gonna make the lad rip off his turn signal wiring. at least inform him about the bullet plugs.:D
    #11
  12. creeper

    creeper Still alive...

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    Aww crap... I forgot. :tb

    I replaced my stockers with waterproof, QD Deutsch connectors when I switched over to the LED turn siggies.

    Sorry Magile... I haven't had to dick around with the stock connectors in so long I forgot about them.
    They are not tough to disconnect... but they are a tiny bit fiddly to work with one hand.

    :dunno... so shoot me.
    #12
  13. Magile

    Magile "What exit?"

    Joined:
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    Exit 163, NJ
    Thnx for punch list. That'll keep me busy for a few weekends. I'm fairly handy but plan to head for the local dealer (Town & Country, Sussex, NJ) if it gets too deep.

    I didn't have to remove the fairing to fit it in the van. We cinched down the forks, tipped it sideways & let the air out of the front tire. It fit fine.

    It looks great in the garage already!

    - Magile
    #13
  14. SamH

    SamH 90S on the bench

    Joined:
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    Tasmania, Australia
    So show us already!
    #14
  15. Magile

    Magile "What exit?"

    Joined:
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    681
    Location:
    Exit 163, NJ
    Here it is, '03 w/ 11,900 miles -
    #15
  16. creeper

    creeper Still alive...

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    I don't see any orange on that front wheel. Go to your local KTM dealer and give 'em the VIN... you're on the list for a new front wheel assembly.

    [​IMG]
    #16
  17. Magile

    Magile "What exit?"

    Joined:
    Apr 11, 2005
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    Location:
    Exit 163, NJ
    Actually, the front wheel has an Excel rim. I bought it from the 2nd owner; he said the front was replaced by the first owner under warranty. I suppose that was the recall issue.

    BTW I was reading the "Air in Front Brakes" thread. My front lever is very spongy. I chalked it up to neglect & added a brake bleed to the to-do list.

    Question - how often do the front brakes need bleeding? :uhoh

    It was a yearly chore on my street bikes, but the comments in the "Brake" thread make it sound like I'll be doing that much more often. :confused

    - Magile
    #17
  18. creeper

    creeper Still alive...

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    Sometimes air gets in the line if the master cylinder is removed or the bars removed and turned upside down... air sneaks past the piston from the reservoir into the line.

    If you dismount the master cylinder and position it so that it's the highest part of the system then walk away overnight, the air in the line finds it's way to the master cylinder where a few light, slow pulls on the lever the next day allows the air to relocate itself back into the reservior... no more spongy brake.
    Works with hydro clutches too.

    The only other way to do it is back or pressure bleeding... but if you don't have the equipment to do that, then the "magic gravity" method works just fine.:D

    C
    #18
  19. Magile

    Magile "What exit?"

    Joined:
    Apr 11, 2005
    Oddometer:
    681
    Location:
    Exit 163, NJ
    Thnx. :1drink

    Just ordered a SW Motech side stand for this critter. Mounts & dismounts are scary, even w/ an empty gas tank & no luggage. :eek1

    I just signed up for the Shenandoah 500 Dual Sport on October 7 & 8. It should be a good break-in ride for me & the 640. Hope to have it in good fettle by then.:clap

    See the Northern Virginia Trail Riders web site (www.nvtr.org)
    for info & the flyer/entry form.

    - Magile
    #19
  20. creeper

    creeper Still alive...

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    Maybe I should build you a little more user friendly seat... ya' think? :wink:

    [​IMG]

    http://www.renazco.com/info.cfm

    C
    #20