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Old 11-04-2006, 12:36 AM   #1
Mulga OP
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Question KTM Part Id?

I took the tank off my 05 640 Adv for the firstime today and found something that looked odd. It's a hose with a bit of steel rod glued and clamped into a piece of stainless steel tube which runs from between the exhaust outlets. I refered to the parts manual and it refers to as a plug (Plug SAS Bore PArt#583.36.024.000), whereas mine is a tube! What the heck is it?



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Old 11-04-2006, 02:14 AM   #2
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The SAS (Secondary Air System) has been partly removed. The rubber tube has been blocked off. The main part that has been removed was bolted to the V - shaped bracket that you can see behind the blocked off tube. It's a bit of a job doing the tidy up part of getting a SAS plug and replacement crushable washer and taking the steel tube out and puting in the plug. Undoing header bolts and exhaust. Just did mine 2 weeks ago. So long as the rod doesn't come out it will be fine.
Check the inlet manifold between the carbie and the cylinder as it would have had a tube coming out of it - the hole should be blocked off with a 6mm bolt or a cap put over the nipple.
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Old 11-04-2006, 04:29 AM   #3
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Yep you can remove the exhaust flange, cut and grind smooth the bracket section. It should look like this
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Or you could order a new flange without the SAS bracket 580.36.040.100
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Old 11-04-2006, 04:34 AM   #4
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The plug installed looks like this.
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The part number for the plug as above is : 583.36.024.000 and matching washer is 584.36.054.000.

A word of warning. When you remove the SAS tube remove the old washer hiding in the head and fit a new one. Also fit new manifold gaskets while you are there. 580.36.041.000

Don't ask me why...

PS. Say goodbye to decel backfires.
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Old 11-04-2006, 04:50 AM   #5
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I may as well finish the story for you.
The part you don't have looks like this
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It attaches to the bracket you have sticking out.
You can clearly see the the soild tube in this picture.
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Sylvia screwed with this post 11-04-2006 at 04:59 AM
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Old 11-04-2006, 04:56 AM   #6
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Also you need to block the vent hole that operated the value. This pic shows the bolt in situ, (centre of picture) It replaces the orignial stem that the vaccumn pipe connected to. The stem connected to the small tube in the above post.
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The part number for the small collar screw bolt is 0015 060083 and the sealing washer that goes with it is 0603 061001
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Old 11-04-2006, 05:01 AM   #7
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And all most back together. Much cleaner now..
Name:  PICT0011.jpg
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Geeze this thread might even make it into the index.
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Old 11-04-2006, 11:09 AM   #8
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Quote:
Originally Posted by Sylvia
...
Geeze this thread might even make it into the index.
Hi Sylvia
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Old 11-04-2006, 11:43 AM   #9
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Lots of this stuff we don't see in the US (we have our own emissions junk to contend with), so having these nice clear pics and descriptions for our SAS burdened friends in other parts of the world will be of great value.

Good show Sylvia. Index this sucker Meat!
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Old 11-04-2006, 12:27 PM   #10
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Done. I put it in setup, noted as SAS removal outside the USofA
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Old 11-04-2006, 01:54 PM   #11
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Thanks Guys,
I'm sure there are plenty of people out there that want to know how to get the SAS off their machines. It soooo fixes the annoying decel issue permanently. No more gas leaks for me, well...
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Old 11-04-2006, 02:00 PM   #12
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Thumb

Cheers fellas.

Exactly what I needed to know
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Old 11-04-2006, 03:49 PM   #13
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Eh?

Quote:
Also you need to block the vent hole that operated the value. This pic shows the bolt in situ, (centre of picture) It replaces the orignial stem that the vaccumn pipe connected to. The stem connected to the small tube in the above post.
[IMG]attachment.php?attachmentid=91047&d=1162645004[/IMG]
Sylvia

I just checked the vent hole on my bike. The origional stem is connected to a hose which runs to the top of the fuel pump. This is different to your description.





I didn't remove the SAS myself, the dealer who I bought it off (Dalby Moto 'Australia's largest KTM Adventure dealer') had set the bike up as a demo. They advertised it as a bike people could ride to get a feel of what a 640 is like set up. So they obviously knew the SAS was a hinderance. Im presuming they knew what they were doing.

What difference in performance would either bike have?

Regards

Dan
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Old 11-04-2006, 04:00 PM   #14
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IIRC Sylvia's 640 is a super moto, it has no fuel pump so the vacum port is blocked. as the ADV has the fuel pump the port is conected to the pump. The non SAS bikes are set up like yours is now, IIRC.

Quote:
Originally Posted by Mulga
Sylvia

I just checked the vent hole on my bike. The origional stem is connected to a hose which runs to the top of the fuel pump. This is different to your description.





I didn't remove the SAS myself, the dealer who I bought it off (Dalby Moto 'Australia's largest KTM Adventure dealer') had set the bike up as a demo. They advertised it as a bike people could ride to get a feel of what a 640 is like set up. So they obviously knew the SAS was a hinderance. Im presuming they knew what they were doing.

What difference in performance would either bike have?

Regards

Dan
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Old 11-04-2006, 07:10 PM   #15
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Thanks for doing the pictures Sylvia, I was going to take some the day i did the SAS Plug but it turned out to be so much "fun" it slipped my mind.
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