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Old 09-04-2006, 01:35 AM   #1
WageSlave OP
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Improved 640ADV c/s sprocket cover

I've had a Touratech countershaft cover sitting in my toolbox for months now. After purchasing it I didn't like the fact that the design did not protect the electrical wiring and brake lines in the manner that the OEM plastic cover does. Therefore I didn't bother to install the T'tech part. I was thinking about listing it on eBAY until the other day.

While riding last week my bike began leaking oil. After the ride I traced the source to the sprocket seal (I replaced the o-ring). In discovering the leak I noted that the sprocket anchoring bolt was loose, most likely the cause of the chewed up o-ring. As other 640ADV owners know, the OEM plastic cover doesn't allow for a quick visual inspection of the c/s sprocket, anchoring bolt, etc... the T'tech cover would though. I wanted to be able to make a quick visual inspection whenever I felt like it. Necessity being the mother of invention I decided to make a better mousetrap. Here are some notes and photos of that process.

As a reference... here's a photo of the T'tech c/s sprocket cover installed. I've circled the area that wasn't protected in the same way as the OEM plastic cover. Also note that this installation replaces the hex bolts, provided by T'tech, with metric OEM-like bolts of the same length. I found that the hex end of the T'tech bolts stripped too easily.


Step #1 - I trimmed the OEM plastic c/s sprocket cover to the desired shape (before and after photos follow).
BEFORE


AFTER


Step #2 - The T'tech cover came with two aluminum spacers. I cut one of them in half, then filed each half down to the necessary height to accomodate this modification.




Step #3 - Assemble the pieces and check for proper fit.


Step #4 - Install on the bike and admire the new and improved c/s sprocket cover!
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WageSlave screwed with this post 09-04-2006 at 01:54 AM
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Old 09-04-2006, 05:59 AM   #2
herobikes
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your images are a no go.
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Old 09-04-2006, 06:56 AM   #3
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Quote:
Originally Posted by herobikes
your images are a no go.
ditto.
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Old 09-04-2006, 08:51 AM   #4
meat popsicle
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The KTM 660 Rallye CS cover is a FREE upgrade!



Why would I want the TT one?
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Old 09-04-2006, 08:59 AM   #5
laramie LC4
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that is nice work. ive often thought about buying that cover but just havent been able to justify the "bling". so instead, i just drilled, filed, and cut out a big circle in the center of the old plastic peice and now i can see the CS.

laramie
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Old 09-04-2006, 10:00 AM   #6
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Very nicely done Waggie. Good idea, write-up and photos... fine workmanship as well.
The TT guard is a bit of a bling to me... but you've taken the two pieces and made something that would be considered by many to be better than either of the individual parts... certainly looks slick.
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Old 09-04-2006, 10:28 AM   #7
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Looks smooth to me. I like it.
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Old 09-04-2006, 11:30 AM   #8
Loadedagain
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wild tim lost a chain on his 2003 640 during the alcan. it ripped his clutch slave off and poked a hole in the side of the engine case. do you think the touratech guard would prevent damage in a broken chain situation?
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Old 09-04-2006, 12:21 PM   #9
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Wageslave - great idea and very well done. May copy it if you haven't applied for the patent.

Dean
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Old 09-04-2006, 04:59 PM   #10
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Quote:
Originally Posted by djchan
Wageslave - great idea and very well done. May copy it if you haven't applied for the patent.

Dean
This great library of Alexandria is for the benefit and betterment of all mankind. For those who seek knowlege and truth, partake then share with others.

I'm just trying to give back a bit in return for all that I've gleaned from this site.

My other goal is to make my ride as bomb-proof as reasonable. Them cockroaches will need a sweet ride after Armaggedon.

Here's my next bit of bling, prior to installation...
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Old 09-04-2006, 05:44 PM   #11
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Nice! Thanks for taking the time to write it up.
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Old 09-04-2006, 05:53 PM   #12
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Quote:
Originally Posted by meat popsicle
The KTM 660 Rallye CS cover is a FREE upgrade!

Howzat?
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Old 09-04-2006, 07:56 PM   #13
meat popsicle
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Quote:
Originally Posted by Gordy
Howzat?
Send sevaral thowsand dollores to mine Nigarian bank account.

(use whatever cutting implement suits your fancy and trim the stock guard to match. if you look closely to the 660s you will notice that it has the same "dimples", most of them, where it was trimmed back from the stocker that you and i get with our rides.)

I like Loaded's query, and second the motion. I wondered if cutting the stock guard like the Rallye bikes would increase the chance of throwing the chain in just such a way... certainly the more you cut the more chance it has of getting around what is left of the cover. I just didn't think the correct forces were there to get it to angle off the drivetrain axis, but maybe if the chain caught a bit of the frame or such when broken it might be all it needs to change course.
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Old 09-04-2006, 07:59 PM   #14
meat popsicle
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Quote:
Originally Posted by WageSlave
This great library of Alexandria is for the benefit and betterment of all mankind. For those who seek knowlege and truth, partake then share with others.

I'm just trying to give back a bit in return for all that I've gleaned from this site.

My other goal is to make my ride as bomb-proof as reasonable. Them cockroaches will need a sweet ride after Armaggedon.

Here's my next bit of bling, prior to installation...
Heya WS,

That must be the old style lower chain guide (parts list compiled by rjf and indexed). Seems like a good upgrade. Two posts that I recall on either side of the fence on that one:

I believe clintnz posted once that he thought the plastic lower guide was responsible for allowing the chain to jump its track, but another (who escapes me at this moment - probably in the indexed thread) thought that the plastic guard might survive some hits better than the aluminum one, which the poster hypothesized would bend and become a liability. Just some thoughts for ya.
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Old 09-04-2006, 08:14 PM   #15
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Quote:
Originally Posted by Gordy
Howzat?
This is howzat.

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