'99 KTM 640Adventure-R rebuild time

[Low594]

Btw, I'm looking to get an all black seat if anyone wants an orange/blue one, its in great shape, just a few tankbag stains and 1 small rip at the usual v at the bottom edge. Cant see the rip when its on the bike.


Another trade I'm looking for is a smaller tank bag, my Wolfman w/sae power port for a GL Buck N Roll?!

[Earthscape]

Originally Posted by Low594

Well, been making progress over the last few days, despite fighting off a cold and possible sinus infection!

Got the EXC throttle assembly installed and the 950 right pod. The pod wasnt as straight forward as I hoped, I had to disassemble it, figure out the wiring and re-terminate 4 wires and re-pin the old Molex plug. One interesting thing I found about the 950 pod, there is a blank panel between the kill and starter swithes & 4 yellow wires in the Molex that dont make it all the way to the pod, tips just taped together hiding in the abrasion tube. Maybe a switch that can be added??
...

The European version of the right side switch for the KTM950 includes a headlight switch. It's a direct plug-in on US 950 Adventures, but I have no idea if it would work on a 640 (don't know if the 640 wiring has a headlight interrupt circuit or not). The switch is available to purchase in the US from several places, but it's not cheap.
http://www.ktmtwins.com/ktm-european-headlight-switch

[Low594]

Originally Posted by Earthscape

The European version of the right side switch for the KTM950 includes a headlight switch. It's a direct plug-in on US 950 Adventures, but I have no idea if it would work on a 640 (don't know if the 640 wiring has a headlight interrupt circuit or not). The switch is available to purchase in the US from several places, but it's not cheap.
http://www.ktmtwins.com/ktm-european-headlight-switch

Ahh! that makes sense! Yea, not worth the trouble or expense, the headlight switch is on the left side, so it's silly to move it over just to be different. But in the future a micro toggle or micro push button might find its way in that spot!

[Low594]

Well got the Hi Beam module out last night, so tonight it was time to put the Model 60 LED module in! These things are super bright!




Here's the links to fellow inmate Sanjoh's LED light thread and ADVMonster, his shop website!

[KFhunter]

I found an 01 640 but it doesn't have the farings like yours, would it be easy to retrofit?

[Low594]

Originally Posted by KFhunter

I found an 01 640 but it doesn't have the farings like yours, would it be easy to retrofit?

Depends on your definition of skill level! You would need the fairing, lights and mounting bracket and then you would have to fab up the mounts on the frame for the mounting bracket. Sourcing them can be another long & expensive ordeal!

Here's another solution, but doesn't look the same!
http://www.advrider.com/forums/showthread.php?t=766161

Yours looks nice tho! The ProMotoBillet tailrack cant be beat!

[Low594]

So I was able to ride the bike today, just down to our weekly coffee. Only about 6-8 miles round trip. The throttle changes were so drastic, it seemed like a whole different bike! Super crisp response and return to idle! It was probably a combination of things, not sure what made the biggest differences. Could have been: questionable old cables, old lube/oil (2 yrs since last lubbed), good new cables, G2 throttle sleeve, fresh cable oil or the Dow33 lube on the throttle tube/assembly.

I should have compared the size of the throttle tube cams. The G2 was marked K100, which lists as stock, but for a 2008 250XCF, not a '99/'01 640A!

Here's what was used:
-'08 250XCF Throttle Housing (77002010100)
-G2 K100 Throttle Tube kit
-'05 640A Throttle Cables
-Smart Parts SL33K/Dow33 lube (yes, paintball lube!)
-Cable Life lube

This reminds me, that my clutch and decomp cables are long over due for a lube!

[meat popsicle]

Originally Posted by Low594

So I was able to ride the bike today, just down to our weekly coffee. Only about 6-8 miles round trip. The throttle changes were so drastic, it seemed like a whole different bike! Super crisp response and return to idle! It was probably a combination of things, not sure what made the biggest differences. Could have been: questionable old cables, old lube/oil (2 yrs since last lubbed), good new cables, G2 throttle sleeve, fresh cable oil or the Dow33 lube on the throttle tube/assembly.

I should have compared the size of the throttle tube cams. The G2 was marked K100, which lists as stock, but for a 2008 250XCF, not a '99/'01 640A!

Here's what was used:
-'08 250XCF Throttle Housing (77002010100)
-G2 K100 Throttle Tube kit
-'05 640A Throttle Cables
-Smart Parts SL33K/Dow33 lube (yes, paintball lube!)
-Cable Life lube

This reminds me, that my clutch and decomp cables are long over due for a lube!

Congratulations!

[YetiGS]

Originally Posted by KFhunter

I found an 01 640 but it doesn't have the farings like yours, would it be easy to retrofit?

I'll let you know in a month or so. I have an '04 625 SXC that I'm making into a 625 "Adventure." I have the tank and the fairing,seat, etc. are on their way to me.

[Earthscape]

Originally Posted by Low594

Ahh! that makes sense! Yea, not worth the trouble or expense, the headlight switch is on the left side, so it's silly to move it over just to be different. But in the future a micro toggle or micro push button might find its way in that spot!

???

Maybe I missed something. That KTM 950 switch is a lights off / parking lights on / headlight on switch, not a high/low headlight switch.
Do you have a different headlight on/off switch on the right side?

[Low594]

Originally Posted by Earthscape

???

Maybe I missed something. That KTM 950 switch is a lights off / parking lights on / headlight on switch, not a high/low headlight switch.
Do you have a different headlight on/off switch on the right side?

Ahhh! I thought it was off/low/high, which I've never liked cause its easy to turn off the headlights when switching from high to low. I need to swap the left controls, since one of the screws is stripped. I found a nice one by K&S (universal fit) which has a high/low switch and a separate off/park/on switch that I was liking. But using the complete 950 assembly is definitely a good option!

[Low594]

It was a busy weekend, but still managed to get a few things done!

Painted the ugly screws black, added the yellow filter to the LED Flood, replaced the windscreen screws with spikes and replaced some of the fairing foam.

Also, finally got the Passmore EZ-Up lever welded on to the centerstand, so much better!

I'm mid way into a major change of the rear turnsignals!

[Low594]

Last night I got the wheels pulled for some new Heidenau K60 Scouts! Also, got the Sharkfin mounted and the old seat pan stripped for the new Seat Concepts foam and cover! I'm also dropping from the 17/40 highway gearing to 15/40 for playing in Death Valley next week!

Also, almost done getting the new Trail Tech Vapor Stealth (kit 75-100) installed, just a few simple issues to resolve!

[bmwktmbill]

Go Low.
bill

[Low594]

More work being done today and through the week, I'll try and remember to take a few pics, I know people like them!

I got the Seat Concepts kit in the mail on Thurs and installed it last night, really nice kit and the price is hard to beat! $185 shipped with the ADVRIDER.COM vender code ($15 off), which is not listed in the vendor discount thread!