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Old 10-18-2006, 07:18 PM   #1
inte OP
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A larger group than usual in Baja.

7 of us are leaving for a quick Baja trip day after tomorrow ...


...seriously guys ... my bike is almost ready. I was working on it today:



See?

I already got the new handle bars on.
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inte screwed with this post 12-28-2013 at 09:42 PM
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Old 10-18-2006, 07:47 PM   #2
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Umm.. I hope you don't need to eat,work or sleep before you leave, otherwise you might be cutting it close!

I'm looking forward to your ride report. Yours always have amazing pics and are fun to read.
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Old 10-18-2006, 07:59 PM   #3
inte OP
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Quote:
Originally Posted by rokklym


Umm.. I hope you don't need to eat,work or sleep before you leave, otherwise you might be cutting it close!

I'm looking forward to your ride report. Yours always have amazing pics and are fun to read.

Looks worse than it is really - just had to replace the head gasket. Getting to the thing requires taking off a ton of stuff, flushing all the fluids, etc...

Actually got the motor back together already - just takes a few hours for the full teardown & rebuild. I've done three of these now, so it's getting easier each time ... at least I think. Final judgement will of course come after I actually fire the thing up...



Only concern is the suspension - it's at Precision. Talked to them today & I'm told it'll be ready tomorrow...if that's the case & it's all working properly - stick the suspension back on & I'm good.

I'm also waiting on a temperature sensor for the head - if that doesn't come in tomorrow I'll just plug the hold with the old busted sensor, bleed the coolant system & run it like that until the new part shows.
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inte screwed with this post 12-28-2013 at 09:43 PM
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Old 10-18-2006, 08:16 PM   #4
inte OP
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good thing about the tear down...

The problem was actually evident.

I replaced what I thought was a blown head gasket on a '95 LC4 - bike wouldn't even run - HUGE amounts of white smoke, even sounded weird. Once the motor was apart everything looked great - including the gasket. Couldn't really explain, so I buttoned everything back up & the bike ran better than ever for the rest of the time that I owned it.

FWIW - that 620 was SERIOUSLY fun ... much more of an aggressive machine than the 640, though arguably more punishing.

I was concerned because I just purchased this 640 on August 25th. It's an '02 with only 1087 miles on it when I took delivery - it had acutally just been registered for the first time in '05 or '06!

So ... this obviously concerned me after my 2nd big ride:




I was told that if coolant sits for a long period of time (as might very well have been the case with this bike) it becomes caustic.

Upon pulling the head gasket, I'm pretty sure that was the case based on the appearance of the gasket & cylinder/head surfaces:













Regarding tackling a project like this ... just take one step at a time ... organize your parts, etc... I like to put the same bolts back in the same exact hole they came out of in the engine - just scrawl a quick sketch of the part your working on, draw circles where the bolts go, & tape them to the paper.




Old boxes work great for storing various parts.

Of course, KTM recommends using Motorex boxes...



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inte screwed with this post 12-28-2013 at 09:44 PM
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Old 10-18-2006, 08:26 PM   #5
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Quote:
Originally Posted by inte
I was told that if coolant sits for a long period of time (as might very well have been the case with this bike) it becomes caustic.
If you question the condition of your coolant, there are test strips available to check acidity. I have a grundle of them on hand.
It doesn't usually go bad in a year or 2, but who's to say? Some of the newer stuff has different additives, and may degrade quicker....
Happy trails in Baja! Leave a l'il Ta-kill-ya behind for my trip in spring!

Hasta!
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Old 10-18-2006, 08:35 PM   #6
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Old 10-18-2006, 08:46 PM   #7
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HEY! where'd you get those fat pegs?!?!?
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Old 10-18-2006, 08:53 PM   #8
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way to rub it in! I will actually be in LA this weekend with no bike. This sucks. I'm waiting for a quality ride report (Like you have ever had any bad one's?)


Nate
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Old 10-18-2006, 08:57 PM   #9
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Quote:
Originally Posted by inte
7 of us are leaving for a quick Baja trip day after tomorrow ...
Bastards!

I'm moving to San Diego...can't stand this feeling that I'm left out all the time!
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Old 10-18-2006, 09:09 PM   #10
Zen Slug
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Quote:
Originally Posted by ktmnate
way to rub it in! I will actually be in LA this weekend with no bike. This sucks. I'm waiting for a quality ride report (Like you have ever had any bad one's?)
I hear dustjunkie has an extra 1150 laying around somewhere






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Old 10-18-2006, 09:14 PM   #11
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Quote:
Originally Posted by Zen Slug
I hear dustjunkie has an extra 1150 laying around somewhere






I could never pilot that bike like him. I would look like I just started riding. Besides, I'll be working. Driving down on Sunday for a meeting and then another meeting Monday then it's back home.
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Old 10-18-2006, 09:15 PM   #12
Zen Slug
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Quote:
Originally Posted by inte
I was working on it today:


And here I was stressing out about putting a new tire and HD tubes on my bike and wondering if it's okay to use wheel bearing grease on the lip of my air filter



At least you've got a garage!
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Old 10-18-2006, 09:16 PM   #13
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I am ready ... 640 is back together w/ my newly reworked suspension. It will be interesting to do the same loop on the bigger bike.

Swiped the fender off the EXC ... cuz it knows the way (always hated the ADV fender)

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Old 10-18-2006, 09:32 PM   #14
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Quote:
Originally Posted by wachs
HEY! where'd you get those fat pegs?!?!?

Fastways
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Old 10-18-2006, 09:48 PM   #15
DirtyVFR
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Counting Down...

7 or 8?
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