KTM Part Id?

Discussion in 'Thumpers' started by Mulga, Nov 4, 2006.

  1. Mulga

    Mulga Been here awhile

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    I took the tank off my 05 640 Adv for the firstime today and found something that looked odd. It's a hose with a bit of steel rod glued and clamped into a piece of stainless steel tube which runs from between the exhaust outlets. I refered to the parts manual and it refers to as a plug (Plug SAS Bore PArt#583.36.024.000), whereas mine is a tube! What the heck is it?

    [​IMG]

    Regards

    Mulga
    #1
  2. Dotbond

    Dotbond Africa, Africa

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    The SAS (Secondary Air System) has been partly removed. The rubber tube has been blocked off. The main part that has been removed was bolted to the V - shaped bracket that you can see behind the blocked off tube. It's a bit of a job doing the tidy up part of getting a SAS plug and replacement crushable washer and taking the steel tube out and puting in the plug. Undoing header bolts and exhaust. Just did mine 2 weeks ago. So long as the rod doesn't come out it will be fine.
    Check the inlet manifold between the carbie and the cylinder as it would have had a tube coming out of it - the hole should be blocked off with a 6mm bolt or a cap put over the nipple.
    #2
  3. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Yep you can remove the exhaust flange, cut and grind smooth the bracket section. It should look like this
    PICT0003.jpg


    Or you could order a new flange without the SAS bracket 580.36.040.100
    #3
  4. Sylvia

    Sylvia vir sapit qui pauca loqui

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    The plug installed looks like this.
    PICT0008.jpg

    The part number for the plug as above is : 583.36.024.000 and matching washer is 584.36.054.000.

    A word of warning. When you remove the SAS tube remove the old washer hiding in the head and fit a new one. Also fit new manifold gaskets while you are there. 580.36.041.000

    Don't ask me why... :D

    PS. Say goodbye to decel backfires.
    #4
  5. Sylvia

    Sylvia vir sapit qui pauca loqui

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    I may as well finish the story for you.
    The part you don't have looks like this
    PICT0005.jpg

    It attaches to the bracket you have sticking out.
    You can clearly see the the soild tube in this picture.
    #5
  6. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Also you need to block the vent hole that operated the value. This pic shows the bolt in situ, (centre of picture) It replaces the orignial stem that the vaccumn pipe connected to. The stem connected to the small tube in the above post.
    PICT0006.jpg
    The part number for the small collar screw bolt is 0015 060083 and the sealing washer that goes with it is 0603 061001
    #6
  7. Sylvia

    Sylvia vir sapit qui pauca loqui

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    And all most back together. Much cleaner now..
    PICT0011.jpg

    Geeze this thread might even make it into the index. :D
    #7
  8. meat popsicle

    meat popsicle Ignostic

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    Hi Sylvia :wave
    #8
  9. creeper

    creeper Still alive...

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    Lots of this stuff we don't see in the US (we have our own emissions junk to contend with), so having these nice clear pics and descriptions for our SAS burdened friends in other parts of the world will be of great value.

    Good show Sylvia. :thumb Index this sucker Meat!
    #9
  10. meat popsicle

    meat popsicle Ignostic

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    Done. I put it in setup, noted as SAS removal outside the USofA
    #10
  11. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Thanks Guys,
    I'm sure there are plenty of people out there that want to know how to get the SAS off their machines. It soooo fixes the annoying decel issue permanently. No more gas leaks for me, well... :D
    #11
  12. Mulga

    Mulga Been here awhile

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    Cheers fellas.

    Exactly what I needed to know:clap
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  13. Mulga

    Mulga Been here awhile

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    Sylvia

    I just checked the vent hole on my bike. The origional stem is connected to a hose which runs to the top of the fuel pump. This is different to your description.

    [​IMG]

    [​IMG]

    I didn't remove the SAS myself, the dealer who I bought it off (Dalby Moto 'Australia's largest KTM Adventure dealer') had set the bike up as a demo. They advertised it as a bike people could ride to get a feel of what a 640 is like set up. So they obviously knew the SAS was a hinderance. Im presuming they knew what they were doing.

    What difference in performance would either bike have?

    Regards

    Dan
    #13
  14. rjf

    rjf SBS's #1 fan in January

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    IIRC Sylvia's 640 is a super moto, it has no fuel pump so the vacum port is blocked. as the ADV has the fuel pump the port is conected to the pump. The non SAS bikes are set up like yours is now, IIRC.

    #14
  15. Dotbond

    Dotbond Africa, Africa

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    Thanks for doing the pictures Sylvia, :clapI was going to take some the day i did the SAS Plug but it turned out to be so much "fun" it slipped my mind.
    #15
  16. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Opps,
    Sorry Dan, yep, what Rhys said. My motor is an SM. The ADV is slightly different, but same principle.

    Performance gains are NIL. Repeat, performance gains are zero, zilch, nada, nothing.

    Some say they experience better, this and that, like starting and throttle response. pfftttttt.
    Personally for me it has achieved 2 things.

    1. I got rid of the dam decel backfires.
    2. I got rid of plumbing I don't want on my motor.

    Personally if I had the head off he motor I would get a professional to weld it up solid. Pumping fresh air into the exhaust is such a lame arse idea, it goes against everything I know in exhaust pipe design. Dam idiots in emissions standards need to leave us alone and pick of the real culprits.
    /rant off

    Sorry, but it gets up my nose somewhat.
    #16
  17. meat popsicle

    meat popsicle Ignostic

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    [​IMG]

    :uhoh
    #17
  18. The Duke

    The Duke Guest

    Hi there, love this forum, such great information. Thanks all. As I newbie and proud new owner of a 99 Duke I hope you can help me get this beast sea worthy - it is in need of a little TLC.

    And as I'm a DIY kind of guy I am getting the basics in order. Filters, oil, sprockets etc.

    First thing, I've found is that the threaded hole for the oil lines into the oil filter cover is cross threaded. OK ordered a new one. But, as Murphy would have it, the last and most inaccessible bolt is not coming out. ItÂ’s already partially rounded. What to do? will a little heat loosen it? If it goes completely round, what then? Short of dropping the motor out, I'm stumped.

    Second thing is, the bike stalls if I put it into gear and although I tried the lever adjustments, its still cuts out. Clutch is definitely grabbing but does not actually slip under acceleration. Strange.

    Finally, the sprockets, they're cactus. The front is 17 but I can't believe its the correct part, as the clearance from the swing arm is way too close for comfort. In fact, it looks like part of the swing arm is chewed out. The metal surrounding the swing arm bearing is considerably thinner on the front face, toward the sprocket. Is this normal? See image

    So guys, would really appreciate a little hand holding while I get to know this weapon. btw where is best for parts, new or 2nd hand, I'm ordering the cover from 'prorider'.

    Cheers
    The Duke

    Attached Files:

    #18
  19. Surly

    Surly surly adventurer

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    I am gonna get rid of this pice of poo poo

    Looks like I need five parts from KTM to do it "right"

    Plug 583.36.024.000
    Washer 584.36.054.000
    Gasket 580.36.041.000
    Bolt 0015 060083
    Washer 0603 061001

    Since I have an adventure what do I do the line to the fule pump?
    Do I plug that too?

    How difficult is it to install that plug? It looks like a press fit if I am seeing what I think I am seeing

    [​IMG]

    FWIW Mine is an 05 bought new in Seattle so this is not a non US "extra"

    thanks folks
    #19
  20. Dotbond

    Dotbond Africa, Africa

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    As for the line from the inlet manifold to the fuel pump i am not sure.
    The washer and plug at the front are just push fit and held in place by the exhaust flanges. Don't forget to dig out the old washer.
    Take a photo of the main SAS unit so we can see if a hose runs off back to the inlet manifold area somewhere.
    #20