ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 12-15-2007, 12:55 PM   #1
Zerodog OP
Beastly Adventurer
 
Joined: Jun 2006
Location: SLC, UT
Oddometer: 1,233
Its winter.....Time to upgrade the Desert Camel

So over the past year or so I have been aquiring lots of parts for my 03' 640A. The bike has 22,000 miles on it now and needs some lovin.
I have put off the projects for one reason or another. Going on trips not wanting to risk changing something, other projects, working on other guys bikes, sick of working on bikes..... But now it is time.

Here is the list:
  • FCR 39 Carb
  • Leo Vince full TI exhaust system
  • Rebuild and Revalve rear shock, (New ideas for valving and new heavier 8.4 spiring.)
  • New 20mm offset Factory Connection triple clamps with rubber mounted bars. ( Hopefully get the front a little less biased and fix my twisted set I have now)
  • New head bearings
  • Change oil and try out some new Base Valve stacks in the forks.
  • New Cycra hand guards
  • New right front LED turn signal
  • Get LED turn signals blinking
  • Weld up Crack in subframe and check for more.
  • Add a support bracket on the right side under the plastic side panel for my Ortlieb saddlebags
  • Change oil
  • Check valves
  • Maybe new clutch? So I don't need to worry about it later this year.
I have got my work cut out for me. But it has been a long time coming. I will take pictures as I go along.
Zerodog is offline   Reply With Quote
Old 12-16-2007, 12:30 AM   #2
bmwktmbill
Traveler
 
Joined: Jul 2005
Location: Traveler
Oddometer: 4,939
Zerodog, don't neglect wheel, swing arm and pivot bearings if you haven't already done them?

Last winter I filled the grooves out of my clutch basket.
So far so good.
Did we ever get to the bottom of if there is such a thing as rally springs for the clutch?

When I looked I could never find a part number that was different on the rally bikes.
b.
__________________
'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
bmwktmbill is offline   Reply With Quote
Old 12-19-2007, 12:25 AM   #3
KenR
Beastly Adventurer
 
KenR's Avatar
 
Joined: Jun 2004
Location: Park City, UT
Oddometer: 1,664
Sounds like a fun winter project. I really want to have a look at the Ti exhaust and I'm curious what you've come up with for that soft bag support - I've been pondering the same thing and have looked at the Dirt Bagz mount.
KenR is offline   Reply With Quote
Old 12-19-2007, 08:07 AM   #4
Zerodog OP
Beastly Adventurer
 
Joined: Jun 2006
Location: SLC, UT
Oddometer: 1,233
KenR you will have to come over sometime and check it out and have some beers.

I just fit up the exhaust last night. It looks pretty sweet and fit on easy enough. The only down side to it over stock exhaust is I loose support on the left side panel. Now I need to work on support on both sides for my saddlebags.
Zerodog is offline   Reply With Quote
Old 12-19-2007, 08:26 AM   #5
cbig
Rift- Raft, SCooter Trash
 
cbig's Avatar
 
Joined: Sep 2003
Location: Orange County, CA
Oddometer: 893
Ron-

looks like you have quite a project! You're gonna love the FCR.

chuck
__________________
Cbig
cbig is online now   Reply With Quote
Old 12-19-2007, 10:58 AM   #6
meat popsicle
Ignostic
 
meat popsicle's Avatar
 
Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
Oddometer: 14,176
Quote:
Originally Posted by Zerodog
KenR you will have to come over sometime and check it out and have some beers.

I just fit up the exhaust last night. It looks pretty sweet and fit on easy enough. The only down side to it over stock exhaust is I loose support on the left side panel. Now I need to work on support on both sides for my saddlebags.
Hey ZD,

Something like this perhaps?

http://www.promotobillet.com/catalog...roducts_id/197

I am tearing into my front and rear suspension. I also have an oil change and some other misc. maintenance repairs as well... I hope to send you my rear shock soon, MP
__________________
Kronreif Trunkenpolz Mattighofen LC4 640

Its not so much staying alive; its staying human that counts.
meat popsicle is offline   Reply With Quote
Old 12-19-2007, 07:59 PM   #7
Zerodog OP
Beastly Adventurer
 
Joined: Jun 2006
Location: SLC, UT
Oddometer: 1,233
The Pro moto billet thing is cool but I don't like it for my setup. And I don't think it will work as good for offroading. Believe it or not I like the bags sitting on the passenger seat zone. They are lower and more central to the bike for a lower center of gravity. They also do not interfere with my back rack for if I choose to carry a ton of other crap on a trip. I don't want to get any more brackets that you can see. So fabricating a frame from .5" tubular steel that hides under my side covers is the way I will go.

Check out the pipes.

This is totally mocked up just to see if they fit. And they seem to fit perfect.


A little different shape then stock. Notice how flat and straight the lower pipe is.


Pre-dented for the FCR carb to fit.....hopefully



Zerodog is offline   Reply With Quote
Old 03-03-2008, 01:35 AM   #8
borsiin
Gnarly Adventurer
 
borsiin's Avatar
 
Joined: Feb 2008
Oddometer: 132
Quote:
Originally Posted by bmwktmbill
Did we ever get to the bottom of if there is such a thing as rally springs for the clutch? When I looked I could never find a part number that was different on the rally bikes.
b.
Clutch springs are harder for the Rally, not much but enough for curing all problems qith slipping. Avaliable from KTM-Sommer in europe.
borsiin is offline   Reply With Quote
Old 03-03-2008, 05:00 AM   #9
humdinger
bp
 
humdinger's Avatar
 
Joined: Feb 2006
Location: South eastern coast , Australia
Oddometer: 616
Pipe dreams..............

The Leo system looks very well made Zerodog! I found the Akro a little 'tight' in areas. The mounting of the muffler is also a little vulnerable like you have stated. The carbon mount loosens with every 'ruggered' mile and creates a bit of play. A second mount is a good idea.
Starter motor housing on my 05 has about 1mm of clearance from the Akro header and the outer fuel pump housing of the FCR (mines a 41 mx) is a little closer than desired. I had a fellow member try my old header (original) on his '98-620 LC4 with the FCR (non mx) and it fits with oodles of room. I think I might have got a P.O.E.T.S (piss off early, tomorrows saturday) pipe out of the Akro factory.

[IMG][/IMG]

[IMG][/IMG]





Big difference with a decent pipe and the FCR isn't it!
I'm about to put a 45 rear sprocket on mine as I could do with a tad more revs down low in the tight stuff.
Still haven't got around to fitting those springs and valve shims.
Gettin' mighty quick at changing diapers though
__________________
'05 640 Adventure
humdinger is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 09:30 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014