KTM 640 Adventure "windshield" removal

[Magile]

I'm hauling a new-to-me 2003 640 Adventure in my Dodge van. Can someone suggest what tools I need to remove the plastic windshield?

The van's openning is 49" high. The mirror's will have to be removed too.

Thnx.
Magile

[rogersboyz]

On my 2005 and my 2006 you need an 8mm socket for the two left and two right bolts in the sides of the main fairing, then the three screws around the top of the instrument panel must come off (don't lose the washers). CAREFULLY seperate the black top of the instrument panel from the lower fairing. There are rubber plugs that hold the pieces together, and the whole setyp is a bit delicate. The lower fiberglass fairing comes off forward, again CAREFULLY. The black top instrument panel stays on the bike.

Good luck.

Jeff Rogers
Rogersboyz@aol.com

[creeper]

Originally Posted by Magile

I'm hauling a new-to-me 2003 640 Adventure in my Dodge van. Can someone suggest what tools I need to remove the plastic windshield?

The van's openning is 49" high. The mirror's will have to be removed too.

Thnx.
Magile

I don't know what "rogersboyz" is smokin'...

But to remove your fairing, all you do is remove all six 6mm bolts with a 8mm socket... then pull up the lower "ears" of the black inner instrument panel, which lifts the locking tabs out of the 4 rubber grommets in the fairing.
At this point, there is nothing holding the fairing in place... you don't have to unbolt the instrument panel.

Pull (flex) the two fairing rear sections outward a bit to clear the mounting bracket... and pull the fairing straight off toward you.

Takes about 3 minutes tops... or less time than it took to write this.
And nothing about a KTM 640A fairing is either "delicate"... or fiberglass.

That's it,
C

[rjf]

Originally Posted by creeper

I don't know what "rogersboyz" is smokin'...
Maybe he has a 2 peice fairing like the older adventure. If its fiberglass it must be a non genuine one.
But to remove your fairing, all you do is remove all six 6mm bolts with a 8mm socket... then pull up the lower "ears" of the black inner instrument panel, which lifts the locking tabs out of the 4 rubber grommets in the fairing.
At this point, there is nothing holding the fairing in place... you don't have to unbolt the instrument panel.

Pull (flex) the two fairing rear sections outward a bit to clear the mounting bracket... and pull the fairing straight off toward you.

Takes about 3 minutes tops... or less time than it took to write this.
And nothing about a KTM 640A fairing is either "delicate"... or fiberglass.

That's it,
C

Creeper speaketh thye trutheth

[SamH]

Mine's got the old 2 piece fairing. Sounds like the only difference is that the old ones have cap nuts holding the instrument pannel in place instead of press lugs.


If it's an old one, undo the 6 bolts and 3 nuts on the instrument pannel and pull the fairing up and towards you (standing at the front of the bike).

Unplug the instrument panel quick connects and the indicators and you're done.

[Magile]

Originally Posted by creeper

I don't know what "rogersboyz" is smokin'...

But to remove your fairing, all you do is remove all six 6mm bolts with a 8mm socket... then pull up the lower "ears" of the black inner instrument panel, which lifts the locking tabs out of the 4 rubber grommets in the fairing.
At this point, there is nothing holding the fairing in place... you don't have to unbolt the instrument panel.Takes about 3 minutes tops... or less time than it took to write this.
And nothing about a KTM 640A fairing is either "delicate"... or fiberglass.

That's it,
C

Thanks C!

I just started combing thru the LC4 index...whew! There's tons of info there.

There are a few things I'll do before hitting the road & trail - replace the chain & sprockets if they're are original, inspect the valves, and do a fresh oil change, any other recommndations?

Gracias,

[SamH]

Get it serviced by a reputable shop, unless you're a confidant home mechanic of course.

[creeper]

Originally Posted by Magile

Thanks C!

I just started combing thru the LC4 index...whew! There's tons of info there.

There are a few things I'll do before hitting the road & trail - replace the chain & sprockets if they're are original, inspect the valves, and do a fresh oil change, any other recommndations?

Gracias,

Assuming (standard paranoia) the previous owner did nothing but maybe change the oil...

• Service all the chassis bearings.(disassembly required)
• Service the Pro Lever. (more disassembly required)
• Battery condition and basic charging check.
• Cable lubrication. (there are only three... and they all go to the carb)
• Nuts and bolts check. (the two bolts that hold the header support bracket to the subframe above the upper chain roller in particular)
• Air filter.

I'll stop here to avoid a complete OCD caliber bike tear-down.

C

[ChrisC]

Originally Posted by creeper

Assuming (standard paranoia) the previous owner did nothing but maybe change the oil...

Nuts and bolts check. (the two bolts that hold the header support bracket to the subframe above the upper chain roller in particular)

Except I'll bet they've gone MIA, so tightening them will be problematic...

[creeper]

Originally Posted by ChrisC

Except I'll bet they've gone MIA, so tightening them will be problematic...

And 6X12mm bolts are sooooooo hard to find.

[2 SPOT]

hey creep your gonna make the lad rip off his turn signal wiring. at least inform him about the bullet plugs.

[creeper]

Originally Posted by 2 SPOT

hey creep your gonna make the lad rip off his turn signal wiring. at least inform him about the bullet plugs.

Aww crap... I forgot.

I replaced my stockers with waterproof, QD Deutsch connectors when I switched over to the LED turn siggies.

Sorry Magile... I haven't had to dick around with the stock connectors in so long I forgot about them.
They are not tough to disconnect... but they are a tiny bit fiddly to work with one hand.

... so shoot me.

[Magile]

Originally Posted by creeper

Aww crap... I forgot.

Sorry Magile... I haven't had to dick around with the stock connectors in so long I forgot about them.
They are not tough to disconnect... but they are a tiny bit fiddly to work with one hand.

... so shoot me.

Thnx for punch list. That'll keep me busy for a few weekends. I'm fairly handy but plan to head for the local dealer (Town & Country, Sussex, NJ) if it gets too deep.

I didn't have to remove the fairing to fit it in the van. We cinched down the forks, tipped it sideways & let the air out of the front tire. It fit fine.

It looks great in the garage already!

- Magile

[SamH]

So show us already!

[Magile]

Here it is, '03 w/ 11,900 miles -