KTM - LC4 Round the World ADVenturization

Discussion in 'Thumpers' started by rtwpaul, Feb 21, 2013.

  1. clintnz

    clintnz Trans-Global Chook Chaser

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    Sounds like you're on to it :thumbThe amount of metal you need to add is fairly minimal really.

    Another thing to think about while modding the subframe is the rack attachment points. I'm currently making new soft pannier racks & stronger tail rack mounts & have bored out the rear bolt holes to take 8mm rather than the std 6mm fasteners which have broken a couple of times.

    Cheers
    Clint
    #81
  2. rtwpaul

    rtwpaul out riding...

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    i was intrigued about this as well as there are a lot of mention of luggage racks adding strength...maybe it was his big endo abilties???

    as for racks can you add a photo of yours to this thread with no bags on them? for reference purposes

    for mine i will probably got with the standard wolfman rack as i will be using their luggage and most of the difficult work has been done, but then i will add bracing and cross bracing plus some triangulation to make it real sturdy just in case it want to take a nap on the trail, but i'll also do some gusset work as well...as the English say "belt and braces"

    as for the tank, having not bought one before i will have to wait and see, but from what i understand the crossbrace is usually made of swiss cheese so that will have to go and something custom thrown together
    #82
  3. gunnerbuck

    gunnerbuck Island Hopper

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    Will do...
    #83
  4. clintnz

    clintnz Trans-Global Chook Chaser

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    They did attach down at the pax peg mount also but were not really rigid enough to provide any support to the subframe:

    [​IMG]

    They cracked at the front mounts once per side, & broke the long cap screws at the back twice, but this was over probably 70K+ km of loaded touring & a few crashes. I just got some 5/8" dia .049" wall 4130 tube to make the Mk2 versions out of & have been machining up some beefier mounting bushes. The new ones will be similar in layout but might be stiff enough to brace the back end a bit.

    I got no idea why my subframe has been less durable than yours Gunner...

    [​IMG]

    :rofl

    I think the first breakage I had owed a lot to Australian corrugations while carrying camping gear & extra gas, although I travel fairly light compared to many. The extra gusset I put in after the 2nd breakage really should have been done during the first repair in hindsight.

    Cheers
    Clint
    #84
  5. Dolly Sod

    Dolly Sod I want to do right, but not right now

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    Not to side track this thread, but do you have any more info on those braces?
    #85
  6. gunnerbuck

    gunnerbuck Island Hopper

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    Here is string of rack pictures:
    [​IMG]
    These are the HB racks on my project bike..
    [​IMG]
    The bracing to the foot peg frame is good but this little strut up to the panel mount seems overkill and makes more of a pain to get the panel off...

    [​IMG]
    The rear portion hangs off a saddle plate made of spring steel which bolts to the rear center subframe cross member and I have a fastener that connects the fender to the rear brace which bolts through behind the license plate...
    [​IMG]
    The HB racks on my project bike are made from heavier stock than the MS units on my main bike pictured below...

    [​IMG]
    The MS also brace to the foot peg bracket but without the extra strut...
    [​IMG]
    How they fasten to the rear...

    [​IMG]
    I like the way the rear fastens to subframe with a box clamp rather than the HBs saddle plate...
    [​IMG]
    Here is the underside showing the clamp, don't mind the mud as this is my daily commuter to work... If I wash this one day it looks the same the next as I have a 30 km comute on dirt tracks to get to my worksite...
    [​IMG]

    [​IMG]
    The Adventure fuel tank bracing..
    f
    #86
  7. rtwpaul

    rtwpaul out riding...

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    i will have to get my bike to look at and compare mounting point to see if they are are all still intact




    thanks for making Sunday great...nothing beats looking at a nice rack :rofl:rofl:rofl:rofl







    :hide
    #87
  8. clintnz

    clintnz Trans-Global Chook Chaser

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    Do Wolfman do a 640 rack? Their stuff does look good, there isn't much available in the way of minimalist soft bag mounts, that's why I made my own, plus a couple of sets for my girlfriend's bikes, some for my bro's 690, some for a friends XT250...

    They were the first set I made with some help from a friend, more details here They are a little flimsy but the material costs were $0 & it's taken me 8 years & 110K km to get around to making something better so they can't be too bad :wink:

    Cheers
    Clint
    #88
  9. rtwpaul

    rtwpaul out riding...

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    wolfman don't make a mount to fit the LC4, but i know the guys there and today i got a PM back from the sales director who agreed to send me a set of mounts unfinished so i can make them to fit, i'll reinforce to the frame on the bike by the passenger mount most likely using 5/8 OD 3/8 ID cm DOM tubing and then as you noted open the hole up to make way for a larger bolt for added strength

    also talking to him they now have a new set of softbags out called Rocky Mountain Saddle Bags they are bigger 32 liters per bag, should be more than enough for everything, might even have to buy some extra stuff to fill them!!!
    #89
  10. bmwktmbill

    bmwktmbill Traveler

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    Wow Guys, Paul,
    This thread grew legs.

    I've been skiing for a couple of days...
    34 miles on skiis yesterday.
    http://www.birkie.com/

    So...much of the discussion of problems on this thread would be solved by trading the SXC for a 640 Adventure.
    In the bargain you get the big tank, a faring that is the best in the business, a cush drive and a BST carb.

    Slap on Touratech panniers and....

    "Tonto, she's already ready to ride."

    Just saying. Trying to be polite.
    bill

    Oops, forgot the lights brothers...dual headlights on the Adventure!!!
    The SXC is not a travel bike, it can be made into one.
    b
    #90
  11. rtwpaul

    rtwpaul out riding...

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    if you walked in my place you'd see i enjoy the build process as much as the thousands of miles on the road, if i'm not doing one then i'm dreaming about the other.

    for me i see adding some structure to the sub frame (i'd do the same on the 640A) tank change and some luggage racks, and i have a few irons in the fire for fairings,

    in realistic terms a few days work and lots of people get to watch and throw in their 2 cents as i do it...sounds like fun to me
    #91
  12. gunnerbuck

    gunnerbuck Island Hopper

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    Paul S has the same bike as you and also runs soft bags, Here is a pic of his made up racks, I'll see if I can find a closer photo:
    [​IMG]
    I suggested he add a spreader brace which goes across the back and under the fender to add rigidity..

    [​IMG]
    #92
  13. slackmeyer

    slackmeyer Don't mean sheeit. .

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    I think your way sounds fun. . . looks like you got a sxc with the BST carb, which is a good carb, but wise to carry some spares of the wear parts (slide, slide guide, emulsion tube, needle). Bill likes his fairing, but I see a lot of complaints about them too. . . I get no buffeting from my LC4-E without any fairing.
    Oil capacity is the most difficult thing- I'd keep an eye out for a used 640 frame with title, but barring that, an oil cooler from a DR or XR-L (I think they had them?) would up the capacity a nice amount.

    FWIW, I know you want maximum range, but with my 18L tank on my 640 i've had no trouble getting 225 miles while traveling (without quite turning on reserve, too). That's running 16/42 gearing, which is as high as I'm willing to go to retain dirt ability.
    #93
  14. MORT666

    MORT666 Been here awhile

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    Hi PAUL nice to see your still traveling the world.No YAMAHA XT660Z then.kTM will do the same engine yes well.:lol3:norton
    #94
  15. AdventureDave

    AdventureDave MMMMM Bundy!

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    [​IMG]

    [​IMG]

    Racks from Dalby moto in Queensland. Made for soft panniers too suit the 625. They move the bags a little further forward than normal racks to centralise the weight. they attach to the pillion peg bracket mount.

    The lights are Baja Design dual 4" HID with mount. A little heavier than std but worth it for me to get good lighting.

    Cheers

    David
    #95
  16. Kawidad

    Kawidad Long timer

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    It seems to me that a filter on the carb breather tube would prevent much of the premature wear on the carb parts. It appears to me that most of the wear is from dirt contamination. :evil
    #96
  17. Adv Grifter

    Adv Grifter on the road o'dreams

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    Those look to be very nice racks for soft bags. One thing I haven't seen addressed here is WHY soft bags are "The Way" ... but I also see some riders attaching them to rather HD racks ... having the Racks take the full weight of bags. IMHO, this a mistake.

    Look at Colebatch and others. They still carry their bags old school "Throw over" style, letting the SEAT take most of the weight. Done this way the racks and attach points don't have to be Super Strong. They are basically there to stabilize bags and keep them off the pipe and out of wheel.

    I would still re-enforce the Sub frame as it's taking all the weight of both racks and bags, top duffel or whatever.

    I see lots of guys using Thick, heavy duty, super strong racks designed to mount Hard Bags to. Why? The Aussie guys have this right. Relatively light racks are all that's required if using Throw Over style soft bags.

    Using throw overs spreads the weight and adds built in "suspension" and damping from the seat foam. Win Win.

    I've gone this way on my DR650 which has survived quite a bit of Baja Washboard in it's 50,000 miles. I did strip one of the attach points from vibes. No cracks, sub frame perfect despite hitting embedded rocks at 60 plus MPH.

    HID 35W light kits would be my lighting choice. Cheap, expendable ... 3 times brighter that stock 55W, saves juice, Plug and play, fits into existing H-4. $12 replacement bulb. $25 for whole kit. 3 years and going on mine.
    #97
  18. Adv Grifter

    Adv Grifter on the road o'dreams

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    Yes, helps to filter the breather, and certainly dirt in there speeds up wear, but according to BST expert Derek, (Motolab) its the rattling of the needle and slide that causes the worst of the wear on the BST.

    I replaced my BST with a whole new Carb (bought low mileage one of Flea Market). Parts were more expensive than the $75 I paid for new Carb. Lots of DR guys sell of their BST's when they go to FCR or TM40 pumpers.

    Wear takes a long time in any case, dirt or not. I swapped out the old Carb at 25,000 miles on my bike. What you notice is some hesitation off idle, bit of surging and very slight loss in MPG. These were my notes on my DR650 when I changed carbs.

    The new Carb was better. No hesitation or surging. But I transferred my Dyno Jet Needle over from Old Carb. It seemed OK ... so it was the slide that showed wear. But a NEW needle every 20K or so miles would be the BEST, according to Derek.

    Dirt DID get into the Carb on mine ... as I was stupid to use Pro Cycles suggested K&N filter on the breather Vent. Mistake. Use oiled foam there. No more dirt in Carb. Once sorted, it's a pretty decent Carb that if run lean enough, delivers over 50 MPH on my DR650 with very good power. :clap
    #98
  19. clintnz

    clintnz Trans-Global Chook Chaser

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    I've started myself a thread on my new pannier rack build for everyone's info. I am trying to brace one side to the other but over the top with a beefier carrier rack mount. I run the bags a fair way forward so a brace out to the rear would be too long. That is another problem with most commercial racks - they have the bags high & way back to accomodate a passenger. If you are riding solo & plan to do some offroad they need to be low & forward.

    Dead right on having the subframe take the weight of the bags directly rather than the racks but I found having a strap over the seat to be a literal pain in the arse. Now for the front strap I have a piece of old seatbelt looped under the seat & hooks on the bags that attach to that. My girlfriend has the same setup on her WR:

    [​IMG]

    Cheers
    Clint
    #99
  20. gunnerbuck

    gunnerbuck Island Hopper

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    Quote:
    <table border="0" cellpadding="4" cellspacing="0" width="100%"><tbody><tr><td class="alt2" style="border:1px inset"> . I am trying to brace one side to the other but over the top with a beefier carrier rack mount. I run the bags a fair way forward so a brace out to the rear would be too long. That is another problem with most commercial racks - they have the bags high & way back to accomodate a passenger. If you are riding solo & plan to do some offroad they need to be low & forward.
    </td></tr></tbody></table>





    For off road riding I absolutely prefer to have my bags mounted rearward and somewhat raised whether running soft bags or hard luggage... A problem arises off road when the bags are too far forward and low which is clipping the back of your leg under the bag when paddling or dabbing over rough ground... This is worse with hard luggage as you can break a leg... With soft luggage it still smarts when you clip that calf muscle as usually the heavy hard items get stowed in the bottom of the bags and that is what slaps you before the bag shifts...

    Sorry for the jabber on your thread Paul, hope to see some of your build pics soon...