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juames 03-19-2013 12:58 PM

640 Refresh
In December I decided that this winter I would give my 640 Adventure some attention. I've owned it for a full season now, and put about 10,000kms on...doing virtually nothing to it except change the oil twice. It has been a blast to ride and never let me down, except during last years Roaming Rally when I took it swimming. Even then after I removed the water from all the places it's not suppose to be, she fired right up as if nothing had happened! I don't have any major work planned...mostly cosmetic (new paint) and preventative maintenance. Basically check all the wheel, suspension, and steering bears. Water pump rebuild, check cam roller bearings, clean carb, replace a few broken bits, etc. Basically give it a good once over that I really didn't do when I bought.

So here is how she looked before the snow started to fall in December. Not too bad really...a few battle scars.

About 45 minutes later, this is how she looked naked. Can't believe how much lighter without the plastic.

And this is how it sat in the garage all winter, until we started to have some signs that spring might actually come. So much for my plan to slowly work away on it over the winter.


bmwktmbill 03-19-2013 10:35 PM

You're gonna need more room on the right.

juames 03-20-2013 06:01 AM


Originally Posted by bmwktmbill (Post 20989628)
You're gonna need more room on the right.

Definitely...the sad reality of having a single car garage...only way to get the car in as well during the winter months. I'm not complain though...small garage is better than no garage. Just wish it was a bit warmer in the winter.

CSF 03-20-2013 10:50 AM

Nice! Looking forward to seeing how this progresses. When are you thinking you'll have it all ready to go and back on the road?

juames 03-20-2013 11:10 AM

I'm hoping for next week. :ricky


juames 03-20-2013 11:27 AM

First thing that I decided to tackle was the water pump. And since the rocker cover has to come off, the area needed a good cleaning.

And from the looks of things it was due for a rebuild. The seal was on it's way out.

Chocolate milk bad...

Bearings were still nice and smooth with no play, but the shaft was starting to show some wear.

gravityisnotmyfriend 03-20-2013 12:08 PM

I trying to do the same thing on my 620. Planned on taking all winter to rebuild her - and now I'm in a rush to get her put back together. Here's how it looked a few weeks ago:

Now, I've taken the back wheel off to replace the back tire.

I did the water pump on mine while it was apart. I found that I had much better luck putting the new seal in with my thumbs. I tried using a press, and it just distorted it.

juames 03-24-2013 05:50 PM

Found the same thing with the seal... Have to take your time and be gentle with it.

juames 03-24-2013 05:54 PM

While I had the rocker cover off I thought I'd check the cam roller bearings. Turns out they are good as new! Smooth, and zero play.

Think they are original, no punch marks.

juames 03-24-2013 06:01 PM

Inspected the ignition switch wiring, as they have been know to fail. But all the solders are still in tact.

Decide to take some preventative steps just in case.

Deadly99 03-24-2013 07:32 PM


CSF 03-25-2013 03:42 AM

I like the silicon fix, that's some good preventative maintenance :thumb.

juames 03-25-2013 03:45 AM

I saw the pictures of broken connections in your thread and figure it was worth the time to take a look, and the silicone should add some extra support.

shipwrek12001 03-25-2013 03:59 AM

your body work looks really slick.... do you have a Graphics kit for it or you running just colour?

juames 03-25-2013 04:02 AM

Ted did such a nice job on the paint, I think it would be a shame to cover it over. Might add a couple small things.

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