Quick release (Zeus fitting) seat for KTM 640

Discussion in 'Thumpers' started by KTM640Dakar, Mar 19, 2006.

  1. KTM640Dakar

    KTM640Dakar Motorsick

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    Has anyone seem a KTM 640 Adventure seat that uses a Dzus quick connector to hold down the rear of the KTM 640 Adventures seat, as opposed to the traditional bolt that is accessed from below the rear tire well. I saw one of these style seats on two Adventures at the KTM North American service head quarters in Amherst Ohio, and thought it was the trickest way to connect the seat to the bike. The zeus fitting attached through the top area of the pad on the rear of the seat. Unfortunately know one was there to ask where the seat came from. I expect that it was from Europe. There is an area under my 2002 640 that has a squared mounting point formed into the plastic of the under-fender that would accept the female zeus mounting plate. I really would like to set my bike up with this style of mounting hardware.

    Any ideas?
    #1
  2. Castleman

    Castleman Guest

    I don't know about the Adventure, but my 625 SMC came with this style of seat, but it only fit's the 9L tank. I don't know if this helps or not.
    #2
  3. ISDT

    ISDT Adventurer

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    #3
  4. Ruffus

    Ruffus Dirty Old Mudder

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    If you know anyone with a Husky,, see how their setup is, you can get the fittings at almost any automotive race shop, then have an ulpholsterer modify your seat to accept it
    #4
  5. Renazco

    Renazco Formerly AKA Boejangles

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    Unfortunately it's not that easy,, you will have to modify the seat, seat base and the mounting attachment.

    On another note the late LC4 Enduro and SXC came with a zuess fastner system but the crown design on the top of the seat is designed to fit just those bikes. Also the early Adventure and of course the 660 bikes came with zuess fittings, all these fasteners are obtainable through KTM.

    I've thought about boring a hole on the 640 seats but it places the bore hole 1/3 of the way into the seat, not good.
    The "Dzus" website recommended above may have something that will avoid using the classic 8mm bolt. My suggestion would be to find a 8mm bolt with a butterfly thumb screw.

    Hope this helps..
    #5
  6. Gummee!

    Gummee! That's MR. Toothless

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    ...or have the 'ears' welded onto the stock bolt...

    Its not like the seat needs to be torqued down!

    M
    #6
  7. Ruffus

    Ruffus Dirty Old Mudder

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    Yeah thats usually my problem,, things usually look easier than they are then offcourse I gotta finish the job & a job that looked like it'll take a week lats 6 months :lol3 ,, anyway I tried, word to the wise, listen to those that know:ear I'm learnin sumthin new almost every day
    #7
  8. Renazco

    Renazco Formerly AKA Boejangles

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    your not alone :cry
    #8
  9. creeper

    creeper Still alive...

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    I just epoxied a 6mm wing nut and plastic "finger extension" onto a 6mm stud. Works groovy.

    [​IMG]

    C
    #9
  10. BlitzBike

    BlitzBike LC4 Pilot

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    That is VERY GROOVEY!
    #10
  11. creeper

    creeper Still alive...

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    Don't get too excited... it's a wing nut and a stud ferchrissakes. The "finger spacer" is whats handy so you can get yer' stubbies onto the whole wingnut.

    [​IMG]
    #11
  12. BlitzBike

    BlitzBike LC4 Pilot

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    I had thought of this too but, never got around to it. The plastic "fingers" extension is nice touch. Where did you get that palastic
    do-hickey?
    #12
  13. creeper

    creeper Still alive...

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    It's just a 35 cent 1/4" ID X 7/16" OD X 5/16" long plastic spacer from the hardware store.

    Maybe I should by 100 of 'em and resell 'em for a buck a throw? :poser
    #13
  14. meat popsicle

    meat popsicle Ignostic

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    There you go thinkin' big again :nono

    You keep that up and you're gonna get yerself inta trouble!

    ps - I have my tool kit with me and use the T-handle. But if this fuse thingey keeps up I might have to to walk that way...
    #14
  15. KTM640Dakar

    KTM640Dakar Motorsick

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    Alright, I searched on KTMworld.com and found the hardware for the 2002 KTM 660 rallye bike. The parts are:
    Quick release Coupling 58307040551 $24 (the male Dzus fitting)
    Thrust bearing Quick release 58307042051 $9 (the female mounting plate that attaches to the rear fender).

    Now I need to figure out how to drill and fit my seat to accept the hardware.

    Bogangles will you build me a seat that will do this?
    #15
  16. Renazco

    Renazco Formerly AKA Boejangles

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    Just shootin off the hip here but it might be easier to use an SXC seat since it's already designed for a Zuess screw, I can trade you a seat if you like?
    Then we get an SXC rear fender which should attach to the Adventure model, me thinks.
    #16
  17. KTM640Dakar

    KTM640Dakar Motorsick

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    Does that seat fit an Adventure tank?
    #17
  18. Renazco

    Renazco Formerly AKA Boejangles

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    I thought I had one in the shop but I'm wrong so I can't compare the two at the moment.

    I'll grab my buddies seat over the weekend and make some comparisons to satisfy our curiosity.

    Either way I'm sure we can come up with something to affix a Zuess, here is an example of some mods we made on a 520 seat pan, just opposite of what your trying to accomplish. The 520 seat has a pair of brackets on the side with two bolts per side, we changed it to a single bolt attachment.
    Basically you can always put the aluminum plate underneath the rear fender to serve as the Zuess attachment point.

    [​IMG]

    [​IMG]
    #18
  19. KTM640Dakar

    KTM640Dakar Motorsick

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    I believe that those two part numbers will cover all of the hardware that I'll need. I just need a seat with a hole on the top rear, that I can fasten the dzus through. There is a molded plastic shelf already formed into the plastic fender well that will accept that hardware. Since I don't ride two up, it won't matter that the dzus fitting pokes up on the rear of the seat. I will try to paste a picture from the schematic that is found under the 2002 KTM 660 Rallye parts page from ktmworld.com.
    #19
  20. markjenn

    markjenn Long timer

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    Hell, I'd bet you could sell 50 here for $5. Sure, you can make your own, but it's a lot easier to paypal someon $5 than to go to the hardware store, source the right parts, and then glue it up.

    - Mark
    #20