Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => KTM LC4 400/610/640 & 690 => Topic started by: KTMRICK on November 08, 2013, 01:41:22 pm

Title: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 01:41:22 pm
The problem with the 640 is that it begs to be ridden just a little harder than other bikes due to its awesome performance and suspension. After a recent 5 day sortie through the mountain kingdom followed by a few local rides, I noticed my pelican top box was rattling a bit. Anyway, turns out the frame was cracked. Googled the problem and it seems to be a known 640 issue with many other cracking in exactly the same place, just behind the rear exhaust mounting. Looks like this after a little cleanup.

Title: Re: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 01:43:46 pm
I phoned a friend and he took me and the bike to an old acquaintance of his who used to be a welder at SAA technical before he was retrenched to make way for younger brighter darker welders! Clever man that he is, he took some machinery as part of his package. Some really serious welding equipment....
Title: Re: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 01:46:37 pm
He manufactured a couple of brackets and welded them on for me in no time for a paltry R200.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 01:50:57 pm
Gave them a quick spray and reassembled the bike in no time at all. If your frame has not cracked yet then apparently, from what I have read, it is only a matter of time before it does, especially if you tour hard with luggage. Unlike Malibu, I sit quite a bit and choose the most difficult lines apparently so the frame takes a bit of abuse. :ricky:
Still the most exciting single I have ever ridden. Just looking at it makes me want to ride.  :ricky:
Title: Re: KTM640ADV Cracked sub frame repair
Post by: BLK on November 08, 2013, 02:09:23 pm
Good to see experienced hands at work.Whos going to weld the planes now?


enjoy
Title: Re: KTM640ADV Cracked sub frame repair
Post by: DeeCeeBee on November 08, 2013, 02:39:19 pm
Good job!

Looks like you bottomed out a few times there on the back shock...judging by the tyre marks on your zoom-pipe :thumleft:
what luggage are you carrying? Hard or soft?
Title: Re: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 02:51:36 pm
I use the Golden Loop as attached and actually travel very light. I had an extensive range of tools in the pelican which was quite heavy I suppose. Subscribe to the "just in case" school of fools.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: KTMRICK on November 08, 2013, 02:54:15 pm
Forgot to mention that I had to relieve some of the inner plastic from the right rear side cover as it was fowling the bracket. A quick pass on the bench grinder did the trick. Ready to ride again!!
Title: Re: KTM640ADV Cracked sub frame repair
Post by: Edgar on November 21, 2013, 10:04:46 am
Daardie subframe sal nooit weer kraak nie!  :thumleft:
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on November 28, 2013, 02:49:52 pm
Where's your welding buddy situated & do you have contact details please.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on February 21, 2014, 10:00:45 pm
Where's your welding buddy situated & do you have contact details please.
Ditto I also have work for him
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on February 28, 2014, 01:49:56 pm
Mine cracked/broke on my Lesotho trip. I got it welded at WAC Offroad Solutions in Kia Sands. Below is what was done to rectify the situation.

Title: Re: KTM640ADV Cracked sub frame repair
Post by: Firecoast on February 28, 2014, 02:01:20 pm
Pardon my ignorance, but how would you know if it is cracked?
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on February 28, 2014, 05:05:53 pm
Mine was obvious, as it was broken.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on February 28, 2014, 05:13:50 pm
Mine cracked/broke on my Lesotho trip. I got it welded at WAC Offroad Solutions in Kia Sands. Below is what was done to rectify the situation.


Pse can you send me their contact detail I need to weld a crack in my bashplate
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on February 28, 2014, 06:33:24 pm
Wayne 083 332 2527
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on February 28, 2014, 08:55:21 pm
Wayne 083 332 2527

Thank you.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: Firecoast on March 02, 2014, 07:14:38 pm
Mine was obvious, as it was broken.

Thanks, that explains it so well.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on April 10, 2014, 07:04:09 am
Here's what mine looked like after being put back on the bike.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on July 03, 2014, 04:53:19 am
BTW Wayne also straightened, painted & pressure tested my radiators for very little money!

 
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on July 03, 2014, 07:52:05 am
Now there's a plan! On mine my temperature varies from77- 92 deg depending on I ride, I have long since thought it's time to take out and clean my radiators.
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on July 03, 2014, 02:24:42 pm
Silverton Radiators will pressure your entire cooling system if you want.

I switched to Evans coolant, so hopefully that'll help.

I've no idea what temperature my bike runs at, as I don't have a temperature gauge, but I've got a Trail Tech on the way from the States to find out. 
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on July 03, 2014, 07:08:57 pm
That's where the fear starts! I have a trailtech. The question you have to ask is how accurate is it and why does it climb so fast?
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on July 04, 2014, 05:04:23 am
Good to know :thumleft:
Title: Re: KTM640ADV Cracked sub frame repair
Post by: evansv on July 04, 2014, 05:14:29 am
I'd rather know, than not know!!
Title: Re: KTM640ADV Cracked sub frame repair
Post by: EtienneKLR on July 04, 2014, 10:19:09 am
Silverton Radiators will pressure your entire cooling system if you want.

I switched to Evans coolant, so hopefully that'll help.

I've no idea what temperature my bike runs at, as I don't have a temperature gauge, but I've got a Trail Tech on the way from the States to find out.  

There is a product called Engine Ice. Very good coolant to use.

http://www.engineice.com/ (http://www.engineice.com/)
Title: Re: KTM640ADV Cracked sub frame repair
Post by: geno.box on January 08, 2015, 11:15:01 am
I'm thinking of doing the subframe work as a precaution

@KTMRICK is your friend willing to help other dogs also? I'm hoping he'd be closer than the guys in Kya Sands (I'm in Centurion)
Title: Re: KTM640ADV Cracked sub frame repair
Post by: Malibu on January 08, 2015, 12:46:38 pm
Unlike Malibu, I sit quite a bit and choose the most difficult lines apparently so the frame takes a bit of abuse. :ricky:

Hahahahahaaaa Using my name in vain again... :)  I bought a bike with the sub-frame already upgraded... (smart chick that I am) and I leave the kitchen sink at home (novelty for a gurl rider) and I stand and do the easier lines (apparently it's better for your bike) :P

Also, as I carry the most fuel, I pack most the heavy stuff on Marks bike (clever gurl). ;D

Thing is, I got a theory, "Get smart first" and then enjoy the ride... >:D
Title: Re: KTM640ADV Cracked sub frame repair
Post by: JMG on January 08, 2015, 08:55:47 pm
I'm thinking of doing the subframe work as a precaution

@KTMRICK is your friend willing to help other dogs also? I'm hoping he'd be closer than the guys in Kya Sands (I'm in Centurion)

For what it's worth I had issues with the side stand on mine, sent it to Wac enduro and they cut and welded it to perfection