KTM 640 Adventure Rally / Adventure Bike Build

[jrozar]

I was in the quest to build a solid middle weight adventure bike but also capable of running a few rally's in Baja this coming year...

I was able to find a 2006 Adventure with 6K miles and in excellent condition. It was used to attack the urban jungle to work and back by the previous owner.

As soon as i got it I took it down for a carb cleaning and rebuild and a good going through by Ken at MTC.

So far here is the progress -

Side Shot-


Scotts Stabilzer and Road Map Holder installed- I am changing the mounting of the Scotts to below the bar in changing the top triple clamp. The bars are a little low for a standing position.



Happy Trails pannier system installed, one of my favorite features of this is that it provides well needed crash protection and triangulates the rear of the bike.



Factory Supertrap exhaust, it will be soon changed out for am FMF Q4, which is sitting in the garage ready to go on.



CNC cut radiator guards



Touatech rear luggage rack-



Scott's Rear Disk Guard



Touratech Skid Plate



Then I took the Bike down to M Power Rally Bikes in Boulder City Nevada and they started working their magic taking it all the way down and have now started putting it back together.

M Power built this 570 Husaberg this year for a friend of mine...



Going back together....all engine & cooling system work completed



Stock lights are getting ready to be pulled and replaced with Dual Vision X Optimus



New Silicone hoses, higher CFM fan and reworked radiator for better cooling...



New Scotts Triple Clamp, Underbar Stabilzer Mount and Bar Riser....



New Pirelli Rally Scorpions....



FMF Q4 installed...replaced the factory Supertrap...

In with the new



Out with the Old



CJ Designs KTM Foot Peg Extension – LONG

http://www.cjdesignsllc.com/products...-peg-extension

I found these and they bolt to the factory KTM pegs and come in standard or long.

They also make them in a weld on version.

We went with the long so that it will allow me put all my weight on the very outside for better traction in corners.

[jrozar]

New front fender bling....



Touratech Chain Guard



Better Shot of the Scotts triple Clamp and Bar risers for Under Bar Scotts Stabilizer Mount



BRP Low Resistance Chain Guide (This is made for the Husaberg but fits the 640, ( if you order one get unit for a '05-08 Husaberg its a perfect fit! )



Bullet Proof Designs Radiator Guards...
https://www.bulletproofdesigns.com/p...or-guards.html



M Power Shock Installed....



What long legs you have.......



Bolt Axle Adjustement Blocks....



Rear Swing Arm with the bling! Chain Guide, axle block, chain guard, new chain.



Hyde Racing ktm Frame Guards





Touratech KTM Front Sproket guard intergrated with the factory plastic cover.



New Chain installed & safety wired clip!



Hyde Frame Guards trimmed & Installed




Engine looking good...



Custom Tuned Ricor Vibranators installed in the bars!

http://www.vibranator.com






Seat Concept Seat Installed, for the long days in the saddle....



Fitting the tank to measure for crash bars and light mounts



Quick side shot before it comes back apart...

[jrozar]

Findley Customs Las Vegas did the paint match for the front rally fender, the stock one had some abuse and we also did a 3m clear guard!





Chris at M Power made an adjustment bracket that can be used to raise or lower the fairing to match the tire.





Chris had an extended wrap over brake line with the Orange Bling made...This line goes over the rally fairing to tie in both calipers.
Waiting for the install picture but you get the idea...it's long and skinny

This is the picture he sent me....



BajaDad came to the rescue with a 640 rally fairing for the build it was off his 2012 Mexican 1000 bike....

Tribute to him in the first pic....

[jrozar]

My Rally Raid Engineering Tank Guards arrived from the land down under...Very nice quality work!

www.rallyraid.weebly.com

The plan is to have the wrap go over the guards but have areas cut out so the CF comes through..







Parts back from AR Iron who did an excellent job with powder coating! These guys are A+ in my book...very reasonable with prices



Crash bars were back from fab, these are Holans and I found them used and abused and had to have them reshaped ......also added two light tabs and had them powder coated at the same time. they will be receiving a set of Baja Designs Adveture Squadrons....



Found another hard to find discontinued part...this is the factory KTM side panel that opens the air box.... Nice extra farkle...



But the the best addition to the build will be adding this last....

[biensur22]

Awesome build. Nicely done.

[betitou]

Holy shit! This is bikers' hard p0rn!!!

[Motorfiets]

[jrozar]

You mean the one next to mine? Im hoping some of the blue rubs off on my Orange...I did put a blue oil filler cap on the 640..

Originally Posted by Motorfiets

[jrozar]

Few more things added today...as the new clutch and high output stator were going in...

Carbon fiber just makes anything look better...I mean provides excellent protection...



Scotts Installed...



Planning to order some Black Zeta handguards with integrated blinkers....when I get off adv this evening...

[jrozar]

Thank you but Les and the guys at M Power do all the work...those guys are good...they took it to the next level....and their suspension is the best KTM suspension around...

Originally Posted by biensur22

Awesome build. Nicely done.

[Kawidad]

Nice!!!!!

With that open airbox side panel, make sure you put a filter skin on the filter. It makes life much easier.

[Yooper_Bob]

[Droptarotter]

That looks great.................hey, why did you choose the FMF exhaust over all the others?

I need something with a spark arrestor.

Cheers

[jrozar]

I have used the FMF Q4 on multiple bikes and have always been pleased with the lower DB sound it produces, its spark arrested and the price. The Akra titanium is nice but for the cost I couldnt justify it... plus if I am worried about weight I will start with losing it off me before the bike, cheaper to diet than buy lighter parts.

Also, HP is not a factor for me with bikes it is a last at best objective, I go for the best suspension, bike protection and my gear first... I may have another new FMF Q4 in the box at the shop for a 640 shoot me a PM if your interested or my factory supertrap is here too.

Originally Posted by Droptarotter

That looks great.................hey, why did you choose the FMF exhaust over all the others?

I need something with a spark arrestor.

Cheers