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Old 04-11-2007, 02:14 PM   #1
alpiv OP
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Joined: Dec 2004
Location: Indianapolis, IN
Oddometer: 2,173
Information please (Rear Shock Removal on a 640 Adv)

Needing information on the correct way to remove the rear shock on the 640 Adv.

Will the spring and reservor pass through the swing arm if I remove the linkage?
Or
Would it be easier to remove the air box and just pull it from the top?
Or
is there a better way?

Help
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Old 04-11-2007, 02:52 PM   #2
jeti
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Oddometer: 7
Rear Shock removal 640 ADV

Try the 'from below' procedure. Just replaced the spring of the rear shock of my 2006 Adv and removing the shock through the hole in the swingarm is easy (when you know what to do..

1) Put the bike on the center stand and for safety-manners place a block under the front wheel to prevent the bike rolling from it's center stand;

2) Remove the right side panel and loosen the nut of the rear brake reservoir (to be able to reach the top bolt of the shock)

3) loosen the nuts on the linkage arms, frame side

4) use some tape to cover the reservoir of the shock, preventing scratches later on

5) place a support under your rear wheel (piece of wood, about 2 inches high) to take away the weight of the rear wheel/swingarm from the shock

6) remove the bolt connecting the shock to the linkage arms

7) remove the left linkage arm Slide the right linkage arm outwards until it touches the frame

8) remove the support under you rear wheel (should now be free of the linkage/shock and move freely up and down) and replace this by a bigger support (like a car-jack). I had to raise the wheel about 6 inches

9) now hold the shock in place with your one hand (or you buddies hand) and loosen the top bolt of the shock. The shock should now be totally free of the frame and the linkage arms

10) lower the shock about 2 inches until it's free of its bracket on the frame and try to rotate the reservoir ccw about 200 degrees towarts the chain, then tilt the head of the shock about 20 degrees to the left, then take it out through the hole in the swingarm . You might need to lower or raise the rear wheel a little to get enough free play but it will work!. Remember the shock's 'attitude' when sliding it through the hole in the linkage....getting it back in place only works in the same way!!!

Takes some patience the first time, but if you get the hang of it you'll need about 10 minutes for shock removal in future.

Good luck!

Jos
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Old 04-11-2007, 04:46 PM   #3
alpiv OP
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Many thanks!

I will update this with photos later.
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Old 04-12-2007, 12:46 AM   #4
bmwktmbill
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Man, I'd take the rear wheel off first....
I do.
Nice to have a milk crate handy.
A pair disposable gloves takes the fear out of the chain.
The pivot is greasy too.
bill.
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
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Old 04-12-2007, 08:35 AM   #5
Zerodog
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I second the rear wheel removal. I like to use a tie down strap to support the swingarm. You can then use it to hold it up so you can work with both hands. The shock needs to be rotated so the res. is pointing into either front corner of the swingarm. Either side works.

I like the tape idea on the res.
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Old 04-12-2007, 11:32 AM   #6
alpiv OP
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Well, it's out!

Many thanks jeti...

It's all being shipped off to http://www.mx-tech.com/.....

I had concerns about shipping it off via Fedx or UPS, yet mx-tech sells a shipping container for $7.50 . You can tell they put some thought into it..


Fill ya in when it all comes back to me.

Rough est for re-valving + new springs is about $650.00 + shipping.
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