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Old 12-04-2005, 12:21 AM   #1
BSTARD OP
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Low Guard/Brake-line Recall 04-05Adventures?

I have seen information on this forum about front wheel lock-up caused by mud and the cross-over brake line/low guard on 04-05Adventures. It happened to me today in the middle of nowhere and all alone (to know me is ta hate me). Lucky 4 me I had the right tools, plenty of water and was traveling rather slowly, hence the bike stayed upright and I was adequately refreshed. I am now officially afraid of this bike. Are KTM gunna wait til someone dies before re-calling/modifying this problem.

After the event I started to think of the numerous times I've been traveling on dirt/gravel roads at speeds well over 100km/h and wondering about the consequences of front wheel lock up. It would only take one rock of the right size to really fuck up ya day.

The first lock up, approx 4k's down the track. Cleaned out mud and went on me merry way.




The second lockup, about 50m from the first one....grrrrrrrrrrrr. As you can see from the pic I only had to make it about 25m to solid ground. So I removed the guard, strapped it to the bike and set off on me merry way again. Wheel locked up within 10m's as the brake-line was locking the front wheel without the guard. Cleaned guard and placed it back on the bike and finally made it to solid ground.




This is all it takes. Not much mud by any stretch of the imagination.




Once I hit solid ground I removed guard and cleaned it again then set off 4 home (about 80km's) with this sense of foreboding that hey maybe the guard has been weakened and any little rock could cause this to happen on the tar at 100+km/h.


It wasn't all bad




Will ring me deala on the morrow and ask him to contact KTM with me concerns. Then I'll ring Dalby Moto and order the high guard mod.
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Old 12-04-2005, 02:07 AM   #2
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I think that swings it for me, I have been thinking of a high guard and brake line mod for a while now.
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Old 12-04-2005, 02:10 AM   #3
braaap!
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c'mon man!..... are you serious?

Page 23 of the manual clearly states: 'Do not ride this motorcycle anywhere that may produce a build up of brown matter between the wheels and the seat - severe personal embarrassment may be a consequence'




get the high mudguard, QED!
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Old 12-04-2005, 02:15 AM   #4
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Quote:
Originally Posted by braaap!
c'mon man!..... are you serious?

Page 23 of the manual clearly states: 'Do not ride this motorcycle anywhere that may produce a build up of brown matter between the rider and the seat - severe personal embarrassment may be a consequence'




get the high mudguard, QED!
FIXED!
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Old 12-04-2005, 02:28 AM   #5
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yup! dats the one, I don't read so good.... and on Page 25:

'if motorcycle performance causes aformentioned 'soiling' condition.. please remove the plug lead to reduce manner of power delivery in the most adverse conditions'
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Old 12-04-2005, 02:57 AM   #6
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Page 26
"when front wheel locks up and tosses you over the bars please remove (at your earliest possible convenience) the brown matter between your anus and ya pants, assuming both your arms still work. In the case of arm malfunction blame the unmistakable stench on the first person to arrive at the scene thus redirecting any unwanted attention from yourself"

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Old 12-04-2005, 03:03 AM   #7
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and who says we men, never ever, read the instructions!
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Old 12-04-2005, 04:24 AM   #8
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Quote:
Originally Posted by BSTARD


Once I hit solid ground I removed guard and cleaned it again then set off 4 home (about 80km's) with this sense of foreboding that hey maybe the guard has been weakened and any little rock could cause this to happen on the tar at 100+km/h. Made it home and had me one of these babies., mmmmm.....beer.

It wasn't all bad.




At least you are drinking the best (light) beer in Australia , IMO.

Have been running a Dunlop 908 front tyre on my 05 ADV , which was picking up rocks and destroying the standard , low guard.

Did the cheap-skates high guard conversion.
Supermoto front guard , SX85 fork protectors and removed right side disc and caliper.
One disc , even with the stock master cylinder works fine , for me.
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Old 12-04-2005, 02:35 PM   #9
BSTARD OP
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Quote:
Originally Posted by scottmoto16
At least you are drinking the best (light) beer in Australia , IMO.

Have been running a Dunlop 908 front tyre on my 05 ADV , which was picking up rocks and destroying the standard , low guard.

Did the cheap-skates high guard conversion.
Supermoto front guard , SX85 fork protectors and removed right side disc and caliper.
One disc , even with the stock master cylinder works fine , for me.

Best beer in the entire world.

Thanks for the info. Think I'll keep both me disc's as I use every bit of power they provide with one finger on the lever.

Will contact Dalby Moto today and order their high guard kit with the supamoto guard.

On a serious note someone's gunna go over the bars when this happens, hurt themselves and damage their bike. If you have this low guard talk to ya deala and let them know about this problem, I'm sure most of them (the deala's)would be aware by now. The more times they here about this problem the less they can ignore it.

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Old 12-05-2005, 12:01 AM   #10
braaap!
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Quote:
Originally Posted by BSTARD
.... On a serious note someone's gunna go over the bars when this happens, hurt themselves and damage their bike. If you have this low guard talk to ya deala and let them know about this problem, I'm sure most of them (the deala's)would be aware by now. The more times they here about this problem the less they can ignore it.
They'll either dismiss it out of hand, or say.... 'shit yeah Man! that low guard is real dangerous..... why don't we do a high guard conversion and we'll pickup the tab for all the new parts and installation labour...'

Yeah right!

More likely,



Whadya expect 'em to do?...
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Old 12-05-2005, 12:56 AM   #11
BSTARD OP
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Quote:
Originally Posted by braaap!
They'll either dismiss it out of hand, or say.... 'shit yeah Man! that low guard is real dangerous..... why don't we do a high guard conversion and we'll pickup the tab for all the new parts and installation labour...'

Yeah right!

More likely,



Whadya expect 'em to do?...

Braap - Destroyer of dreams, smasha of illusions, bringa of reality....you bastard

Ordered the high guard from Dalby today($330) before speakin with me deala as I would prefer to do this face to face. I'm sure, he will at least ring KTM with yet another complaint about the low guard, that's all I can really ask.

Don't think he will tell me to "eat him" as I've purchased 2 bikes from him this year as well as spendin a few thousand on accessories/services.

PS: thanks for the tyre info.
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Old 12-05-2005, 01:22 AM   #12
braaap!
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my Parole Officer thinks I'm a nice guy deep down, too!... like, six feet down!

I'd be interested to know the 2nd brake line part number you get, I was fobbed off with a SX85 line and it aint right! the banjo at the master cylinder isn't cranked over enough so I got this big dumb ass loop above my bars that grows when the forks stroke thru.... shits me!

I'd really like to have a single line from the m/cylinder down to a T-piece / union at the lower triple clamp, then 2 lines down to calipers... sounds tidier?

What color SM guard?
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Old 12-06-2005, 05:01 AM   #13
Trevor S
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Quote:
Originally Posted by BSTARD
I have seen information on this forum about front wheel lock-up caused by mud and the cross-over brake line/low guard on 04-05Adventures.
I must admit to being bemused by this.... would you ride a GSX-R1000 in conditions that did not suit it and then blame Suzuki ?

I can't believe anyone seriosuly thinks the stock guard can handle mud ? I changed it out before I even took delivery of my KTM 640 Adv ... I rode miles of black soil last weekend (had dried out for about 3 hours so we were able to get through, just) with mud nearly the entire thickness of the high guard, the low guard would have been a joke.

Running the low guard is fine but you HAVE to re-do the brake lines so you can unbolt it as soon as you see mud. In your situation, after I slapped myself in the head for not getting a high guard I would have stopped, removed both front calipers cable tied 'em to the handle bars and taken the guard off before I got into the mud...either that or turned around.

I really can't see how you can blame KTM ???? Sure the design sucks... and they shoudl have kept the '03 front end... but I have yet to come across a bike that doesn't have something about it that sucks.. and this is pretty minor IMO.
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Old 12-07-2005, 04:35 AM   #14
BSTARD OP
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Quote:
Originally Posted by Trevor S
I must admit to being bemused by this.... would you ride a GSX-R1000 in conditions that did not suit it and then blame Suzuki ?

I can't believe anyone seriosuly thinks the stock guard can handle mud ? I changed it out before I even took delivery of my KTM 640 Adv ... I rode miles of black soil last weekend (had dried out for about 3 hours so we were able to get through, just) with mud nearly the entire thickness of the high guard, the low guard would have been a joke.

Running the low guard is fine but you HAVE to re-do the brake lines so you can unbolt it as soon as you see mud. In your situation, after I slapped myself in the head for not getting a high guard I would have stopped, removed both front calipers cable tied 'em to the handle bars and taken the guard off before I got into the mud...either that or turned around.

I really can't see how you can blame KTM ???? Sure the design sucks... and they shoudl have kept the '03 front end... but I have yet to come across a bike that doesn't have something about it that sucks.. and this is pretty minor IMO.

Everyone's got one(an opinion), and yours has been noted.

I was going to leave it at that but narrrrrrrrr.

GSX-R1000
WTF, Lets keep the apples with the apples and the oranges with the oranges shall we!

This is the only pic in the brochure with the 640A on the dirt. They say a picture tells a thousand words, is this KTM's way of telling the consumer that in order to ride this particular motorcycle on the dirt you need to mod it to this state?

KTM's words from the 2005 brochure.
"Wherever in the world strange continents, lonely desert expanses or wild
jungle trails - the KTM 640 Adventure is the ultimate, single cylinder
travel motorcycle."
I understand that this is advertising hype, and no I don't believe everything I read, but none of the information I'd seen or been told before I purchased my "dual-sport" bike with 300mm of suspension travel said that it should not be taken on any road that may contain mud. If only I possessed your magnificent level of foresight.....can I have the lotto numbers?

The reason I started this thread was to let others know that yes it is a problem. Could you please point out the part where I blamed KTM for this? If KTM knows this to be a problem they should sell the bike with either a high guard already installed or an optional kit. If they don't know this to be a problem then we as consumers of their product need to tell em, otherwise nothing will change. If KTM isn't responsible for the stuff they design and sell then who the fuck is? How many years did they hold back on the front wheel recall? How many years will they hold back on this one?

IMHO the removal at the most critical safety component of you bike, that being BOTH brake calipers in the middle of nowhere is just plain dumb, but that is after all just my opinion.

I would also be interested in your opinion on these guys.

And just in case you think your gear or bike isn’t up to the challenge:
http://www.advrider.com/forums/showthread.php?t=29723
Guess what, its not the gear…

Oh yeah, I have dual-sport tyres on me bike and me WRX has a tow bar, folks are dumb where I come from.

These are great bikes, it's my second KTM and I'd buy another. As I find other problems with the bike I will fix them from my own pocket. I will also let my dealer know so he can then make a choice to pass the infomation onto others, that's entirely up to him.


Cheers.


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