640 ADV Forks

The Misinformant · 11-04-2007, 01:36 AM

Has anyone changed the springs themselves on the 4860WP forks? Is there any special tools required and is it a reasonable easy job?

Have found a set of .46 WP springs out of a 06 640 to replace my .44 WP springs in my 03 640 ADV - which we think are a direct swap.

Laromonster · 11-04-2007, 01:17 AM

Arent the 03 forks 43mm and the 06 48 mm ?

The Misinformant · 11-04-2007, 02:05 AM

My owners manual says 4860, so I assume they are 48's. Let me look in the shed.

GodSilla · 11-04-2007, 02:17 AM

The '03 model got the hi-flow head and the rally 48mm forks, from memory.

The Misinformant · 11-04-2007, 02:26 AM

Yep books say 48mm. Can't measure them tonight as it not here. Bloody squids!

Para504 · 11-04-2007, 03:43 AM

My '02 has 48mm (measured them to be sure) as well. The literature is notoriously wrong!

Luke · 11-04-2007, 01:47 PM

Quote:

Originally Posted by The Misinformant

Has anyone changed the springs themselves on the 4860WP forks? Is there any special tools required and is it a reasonable easy job?

Have found a set of .46 WP springs out of a 06 640 to replace my .44 WP springs in my 03 640 ADV - which we think are a direct swap.

It's pretty easy, there was one special tool that I needed. In order to separate the top cap from the bottoming bumper, I needed to grind down a wrench so that it was thin enought to slip onto the flats on the bumper's nut. I think it was a 15mm wrench.

Zerodog · 11-05-2007, 09:52 AM

Yes the 03 has 48mm forks. They are pretty much the same fork as the MX bikes. They just have a slightly shorter stroke on the cartridge. That is why they take the shorter springs. The 510mm springs will also work if you remove all the preload spacers except the thinest one. They are also the same interally as the 07 640. The .46 will most likely still be too light. But it will still be an improvement.

11-04-2007, 01:36 AM	#1
The Misinformant ^OP What road? Joined: Jun 2004 Location: Adelaide, Australia Oddometer: 348	640 ADV Forks Has anyone changed the springs themselves on the 4860WP forks? Is there any special tools required and is it a reasonable easy job? Have found a set of .46 WP springs out of a 06 640 to replace my .44 WP springs in my 03 640 ADV - which we think are a direct swap.

11-04-2007, 01:17 AM	#2
Laromonster Vesperado ! Joined: Jun 2004 Location: Stavanger Norway Oddometer: 1,255	Arent the 03 forks 43mm and the 06 48 mm ? __________________ Laromo '91 Vespa PX 200E "Lusso" '05 KTM 640 ADV "Fatman" '99 HD FLHRCI "Leviathan"

11-04-2007, 02:17 AM	#4
GodSilla I did that. Joined: Sep 2006 Location: The Promised Land Oddometer: 6,442	Big forks on '03 The '03 model got the hi-flow head and the rally 48mm forks, from memory.

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11-04-2007, 02:05 AM	#3
The Misinformant ^OP What road? Joined: Jun 2004 Location: Adelaide, Australia Oddometer: 348	My owners manual says 4860, so I assume they are 48's. Let me look in the shed.

11-04-2007, 02:26 AM	#5
The Misinformant ^OP What road? Joined: Jun 2004 Location: Adelaide, Australia Oddometer: 348	Yep books say 48mm. Can't measure them tonight as it not here. Bloody squids!

11-04-2007, 03:43 AM	#6
Para504 Spam, Spam, bacon & Spam! Joined: Sep 2005 Location: Cow Hampsha, USA Oddometer: 539	My '02 has 48mm (measured them to be sure) as well. The literature is notoriously wrong!

11-05-2007, 09:52 AM	#8
Zerodog Beastly Adventurer Joined: Jun 2006 Location: SLC, UT Oddometer: 1,233	Yes the 03 has 48mm forks. They are pretty much the same fork as the MX bikes. They just have a slightly shorter stroke on the cartridge. That is why they take the shorter springs. The 510mm springs will also work if you remove all the preload spacers except the thinest one. They are also the same interally as the 07 640. The .46 will most likely still be too light. But it will still be an improvement.