Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => KTM LC4 400/610/640 & 690 => Topic started by: axehead on May 17, 2011, 11:19:25 am

Title: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 17, 2011, 11:19:25 am
Got my new bike today. To call it a challenge is an understatement  :o

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/227334_10150272812242289_690747288_9035740_2905210_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226748_10150272812372289_690747288_9035741_662390_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/226999_10150272812452289_690747288_9035742_8225276_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226866_10150272812572289_690747288_9035744_2087695_n.jpg)
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/226390_10150272812947289_690747288_9035751_48022_n.jpg)

Better go download a manual or two  :biggrin:

Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: ktmmer on May 17, 2011, 11:22:15 am
Where did you find this and for how much if you dont mind? I have been looking for a 640 rebuild for a very long time.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Rufus115 on May 17, 2011, 11:55:03 am
Where did you find this and for how much if you dont mind? I have been looking for a 640 rebuild for a very long time.

Yeah, come on, out with it, I wanna hate youi and need to know why!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 17, 2011, 12:09:18 pm
I live in Dubai and got it there through my friendly local bike shop.

I didn't actually pay for it, just a bit of bartering for some things I didn't need anymore ;)

Only thing was I had to promise not to bring it back to the bike shop for help!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 17, 2011, 01:13:21 pm
Fixed!  :biggrin:

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230515_10150272861347289_690747288_9036095_5419735_n.jpg)



Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Archangel on May 17, 2011, 01:40:01 pm
Nice wheels  :biggrin:

Subscribe 


:happy1:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Kenisis on May 17, 2011, 01:41:43 pm
I live in Dubai and got it there through my friendly local bike shop.

I didn't actually pay for it, just a bit of bartering for some things I didn't need anymore ;)

Only thing was I had to promise not to bring it back to the bike shop for help!
Hey Axe Head.

Which shop in Dubai? Do they have anything else. I may also want to do a Project bike. I am looking at an Africa Twin at the moment but if they have another KTM i would be interested.

Cheers
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: domstes on May 17, 2011, 01:42:50 pm
I likes!  :happy1:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Dwerg on May 17, 2011, 02:07:54 pm
 :happy1:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: ianb on May 17, 2011, 02:19:22 pm
That looks like a 1998/9 model . I had one , nice bike .Good luck with your project.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 17, 2011, 04:51:50 pm
Kenesis : Sourced through Sebsports. Seb has an AT in there at the moment, owner by some Italian guy I think. He wanted to put it back on the road after being laid up, so maybe would take an offer.

I know of 3 x AT in Sharjah, plus an old Tenere or two. I don't know any more KTMs around though sorry.

Ianb : I don't even know what year it is yet, but I think your estimate is close  ;)
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Kenisis on May 17, 2011, 04:54:35 pm
Kenesis : Sourced through Sebsports. Seb has an AT in there at the moment, owner by some Italian guy I think. He wanted to put it back on the road after being laid up, so maybe would take an offer.

I know of 3 x AT in Sharjah, plus an old Tenere or two. I don't know any more KTMs around though sorry.

Ianb : I don't even know what year it is yet, but I think your estimate is close  ;)

Thanks boet I will go past there during the week and have a look.

Cheers
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Ronsard on May 17, 2011, 06:23:15 pm
 O0
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: alli on May 17, 2011, 07:45:25 pm
Hey Axehead

At least my strip down was self inflicted, you're going to have to fix someone else's madness. Let's hope you got all the pieces mate.

Good luck with the build :thumleft:

I'll be watching.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 22, 2011, 10:01:43 pm
Still waiting to see if I can get the papers for this bike. You cannot register without the papers here.

If I can't get them I think I will part this bike out. To be determined.

Anyway, my labour is free so I started trying to sort the bits out on the weekend.

Decided to start with the rear wheel, seemed as good a place to start as any.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/227517_10150277948992289_690747288_9078111_5581927_n.jpg)

Nice way to start, the rear axle is bigger than the hole in the wheel, as well as the calliper. Curtain rod will do the trick for now.

Got her up on her own 'feet'

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/247638_10150277949127289_690747288_9078113_4616022_n.jpg)

Decided to work out where these random electrics go

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226782_10150277949422289_690747288_9078118_728597_n.jpg)

The end with the orange capacitor goes at the dash end. The rectangle connectors are mostly for lights and controls. Two empty ones go to the rev counter/ display.

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/247771_10150277949687289_690747288_9078123_7714483_n.jpg)

Multi coloured spaghetti everywhere

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/230436_10150277949857289_690747288_9078126_3479106_n.jpg)

The other end of this loom goes to the rectifier/battery/rear brake etc

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229341_10150277950277289_690747288_9078132_4419868_n.jpg)

Decided this mount/bracket thing was not standard and removed it

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227196_10150277949967289_690747288_9078127_6015856_n.jpg)

Using the two bolt holes now vacant from the aluminium bracket I added a steel bracket

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/248446_10150277950107289_690747288_9078129_7390368_n.jpg)

To the steel bracket I added a loop that goes in front of radiators and the headlight. The loop also has two bungs for fuel tank support

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/231111_10150277950677289_690747288_9078137_8335260_n.jpg)

Not sure if these are standard or not, but they are KTM hardparts that are some sort of light mount support

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225366_10150277949547289_690747288_9078120_6321351_n.jpg)

Front end axle seems to be the right size for the forks. Hard to work out how the front wheel is missing but I have the correct axle. The rear wheel is there but the correct axle and adjusting blocks are missing!

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/229036_10150277950452289_690747288_9078133_7041155_n.jpg)

Thats it for now. Got 2 other bikes to work on and it's getting very hot here. Will need to move inside for summer soon!
























Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 22, 2011, 10:02:44 pm
Hey Axehead

At least my strip down was self inflicted, you're going to have to fix someone else's madness. Let's hope you got all the pieces mate.

Good luck with the build :thumleft:

All too true mate. You want to buy a KTM?  :biggrin:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Paulsky on May 22, 2011, 10:07:49 pm
Very cool project, please keep posting, I like
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 22, 2011, 10:14:27 pm
A list of things I have worked out are either missing or broken:

* Front wheel complete
* Rear axle and adjustment blocks
* Chain slider
* Front sprocket cover
* Swing arm upper chain guard
* Battery
* Air intake snorkel
* A shed load of bolts
* Key and ignition barrel
* Registration papers
* Oil pumps (1 or 2 reportedly missing or damaged, TBC)
* Front fork internals (maybe some parts missing, some definitely rusted)
* Brake and clutch levers bent
* Hand guard mount brackets broken (2)
* Tool box and tools (mounted opposite exhuast)
* Turn indicators
* Air intake rubber boot (cracked)

I am sure more will be added to this list as I go along.....


Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 22, 2011, 10:19:11 pm
I was also thinking about buying a complete front end off a 530EXC or similar. All I would need then is to machine up a bolt to mount the triple clamps correctly.

Not sure how clever/stupid that idea is yet. Would end up with upside down forks and maintain a similar travel and 21" front wheel.

The main factor is that it would be a lot more common part to find here. Comments welcome  :biggrin:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: TheAnt on May 23, 2011, 06:39:02 am
Subscribed!!!  :ricky:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: letsgofishing on May 23, 2011, 08:45:56 am
That's some project you've taken on there!
Looking forward to following this thread  :thumleft:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 23, 2011, 09:00:21 am
That looks like a 1998/9 model . I had one , nice bike .Good luck with your project.

The 8th last digit of the VIN is a W. This indicates an 98 model  ;)

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250409_10150278570192289_690747288_9084394_3686463_n.jpg)
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 23, 2011, 09:01:34 am
And to provide inspiration, and a little bit of torture, here is a clean example  :biggrin:

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/247571_10150278570092289_690747288_9084393_5524709_n.jpg)
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: alli on May 23, 2011, 09:51:32 am
I think this is an aftermarket rally bracket for ICO/road book etc
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 23, 2011, 06:29:43 pm
Yeah, I figured it must have been for mounting stuff like that, but cant work out how the fuel tank is supported if the mount for the tank is fixed to the other bracket that is removed to put on the ally bracket.  ???
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 25, 2011, 06:05:54 pm
Still not 100% sure, but it looks like I won't be able to get a title for this bike.  :(

Wondering if I can get a frame with a title, or maybe part the bike out.

Watch this space if you want dibs on any parts  ;D
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Welsh on May 25, 2011, 07:47:28 pm
Check the South African sticker on the swing arm :biggrin:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: ktmmer on May 26, 2011, 08:36:21 am

Watch this space if you want dibs on any parts  ;D

I will gladly take the whole bike off your hands !!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 26, 2011, 09:25:24 am
got a DS bike to swap for it?  :biggrin:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: ktmmer on May 26, 2011, 09:42:45 am
950 SE acceptable   ;D
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 27, 2011, 11:13:57 pm
Some new photos - looks like the front end is back together:

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/250448_10150283704102289_690747288_9128929_4860348_n.jpg)

But what's that big curly pipe behind the forks?

Ahhhh :

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/246934_10150283704277289_690747288_9128932_3348310_n.jpg)

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/251298_10150283704502289_690747288_9128935_5413097_n.jpg)

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/249732_10150283998357289_690747288_9131103_8101222_n.jpg)



Going for the title of world's longest range 2T  :biggrin:




Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: alli on May 28, 2011, 09:18:44 pm
Worlds first KTM 300 exc adventure.
limited stock.
To avoid the rush, place your orders here folks. ;D.

Hmmm, I think that front end would look much better on my little DR :mwink:
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Ronsard on May 29, 2011, 06:36:39 am
i tought it was a 640???
 ??? ??? what is going on??
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: LouisXander on May 29, 2011, 06:18:55 pm
Ja, ek ook, nou sien ek die expansion chamber pyp!!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 29, 2011, 06:27:21 pm
i tought it was a 640???
 ??? ??? what is going on??

Still not 100% sure, but it looks like I won't be able to get a title for this bike.  :(

I can't register the 640. I don't see much point in a bike that big to only ride in the desert. So I am thinking about dual sporting a 525 EXC.

Just using the 2 stroke for measurements.

Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: LouisXander on May 29, 2011, 08:27:09 pm
Search this section. Sidetrack has a 525 that he is continuing to DS on a daily basis! I rode it, and it was damn fine!!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Berty77 on May 31, 2011, 01:00:40 am
Part the damn thing, its giving ME headaches!! I hate puzzles/tettris.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on June 27, 2011, 11:15:29 pm
Just before I workout out I wanted a 525 I sold mine to a mate.

Luckily he has a short attention span so I bought it back for the same price. He even serviced the shock and added new plastics and side stand for me  :biggrin:

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/260305_10150316380927289_690747288_9433275_2423880_n.jpg)

The bike already has an HT racing oil cooler added.

So from the 640 I will take the cush drive rear, tank, fairing.

I was thinking about adding a 540 kit from thumper racing along with a hot cam, and fluidyne radiators.

But first I will get around to putting it together.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on July 06, 2011, 08:48:07 pm
The best thing about having a vague plan is that sometimes thing change.

I bought a 640-E today with only 2200km on the clock. With a title! So with any the E will turn into an ADV. And I will have a few spares incase something goes horribly wrong. The good news is the title only lists the frame, so either engine can go in without any headaches.

Should be finished in about 3-4 years  :biggrin:

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/271130_10150326790447289_690747288_9529569_3993486_n.jpg)
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: buzzlightyear on July 06, 2011, 09:10:13 pm
Nice, that bike looks good. Now that I see the kickstarter, I kickstarted a 640 once, was not difficult with the decomp, but weird with the left leg  ;D
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on July 06, 2011, 09:16:06 pm
There is a big thread on ADV rider about it. They recommend to stand beside the bike and use your right leg.

I am left handed though (and left footed?) so might try to see how it feels on the bike.....
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on August 07, 2011, 05:39:47 pm
After a long interim, the bike is legally mine.....

Too hot outside so will be moving my workshop inside  :thumleft:

Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: axehead on May 26, 2012, 07:32:29 pm
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/556950_10151024697087289_690747288_12364863_1749986428_n.jpg)

Don't think it will ever be 'finished' but I now have a complete & running bike. Only taken a year to get this far, but a lot of other things have gone down in that time.

Went for a little shake down run today, few items still need sorting.
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: letsgofishing on May 29, 2012, 04:02:08 pm
Congrats - looking good!
Title: Re: 640 Adventure Project (3D Jigsaw Puzzle)
Post by: Dwerg on May 31, 2012, 01:21:22 pm
Impressive considering the pile of crap you started off with  :thumleft: