Welcome, Guest. Please Login or Register

Author Topic: 640 Adventure Project (3D Jigsaw Puzzle)  (Read 2734 times)

0 Members and 1 Guest are viewing this topic.

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
640 Adventure Project (3D Jigsaw Puzzle)
« on: May 17, 2011, 11:19:25 am »
Got my new bike today. To call it a challenge is an understatement  :o







Better go download a manual or two  :biggrin:

 

Offline ktmmer

Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #1 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.
 

Offline Rufus115

Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #2 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!
"To live, you gotta lose some sleep"
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #3 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!
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #4 on: May 17, 2011, 01:13:21 pm »
Fixed!  :biggrin:





 

Offline Archangel

  • Admin & Commercial
  • Senior Member
  • ***
  • Bike: AJS (all models)
    Location: Western Cape
  • Posts: 3,866
  • Thanked: 48 times
  • Of maar net Gabriel
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #5 on: May 17, 2011, 01:40:01 pm »
Nice wheels  :biggrin:

Subscribe 


:happy1:
« Last Edit: May 17, 2011, 01:43:45 pm by Archangel »
 

Offline Kenisis

  • Senior Member
  • ***
  • Bike: KTM 990 Adventure
    Location: Other
  • Posts: 1,482
  • Dubai
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #6 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
2012 KTM 990 Adventure
2015 KTM Rally Replica
2016 Husqvarna FE 450
2017 Husqvarna FC 450
 

Offline domstes

  • Senior Member
  • ***
  • Bike: KTM 990 Adventure
    Location: Western Cape
  • Posts: 1,511
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #7 on: May 17, 2011, 01:42:50 pm »
I likes!  :happy1:
 

Offline Dwerg

  • Moderator
  • Bachelor Dog
  • *****
  • Bike: KTM 690 Enduro
    Location: Gauteng
  • Posts: 10,977
  • Thanked: 185 times
    • Wise Web Worx
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #8 on: May 17, 2011, 02:07:54 pm »
 :happy1:
Current: KTM 690R
Previous: KTM 790ADV, 640ADV, 950ADV, 250XCW BMW F650GS Single, F650GS Twin, F800GS, G450X, R50/2 Honda CRF450X, CRF230 x 2, VFR400 NC30, Z50 Mini Trail Yamaha BWS100 x 2, LB80 Chappy
 

Offline ianb

  • Senior Member
  • ***
  • Bike: BMW R80GS
    Location: Kwazulu Natal
  • Posts: 1,677
  • Thanked: 43 times
  • BMW R80GS. KTM 790R
    • BLOMEYERS
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #9 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.
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #10 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  ;)
 

Offline Kenisis

  • Senior Member
  • ***
  • Bike: KTM 990 Adventure
    Location: Other
  • Posts: 1,482
  • Dubai
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #11 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
2012 KTM 990 Adventure
2015 KTM Rally Replica
2016 Husqvarna FE 450
2017 Husqvarna FC 450
 

Offline Ronsard

  • Senior Member
  • ***
  • Bike: BMW F650GS / Dakar
    Location: Gauteng
  • Posts: 999
  • never ask why...ask why not
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #12 on: May 17, 2011, 06:23:15 pm »
 O0
 

Offline alli

  • Senior Member
  • ***
  • Bike: Kawasaki KLR 650
    Location: Gauteng
  • Posts: 1,391
  • Thanked: 1 times
  • Where to next?
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #13 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.
GONE INSANE.....BACK SOON

KLR650 & DR350S & XR600R
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #14 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.



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'



Decided to work out where these random electrics go



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.



Multi coloured spaghetti everywhere



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



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



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



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



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



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!



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!
























 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #15 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:
 

Offline Paulsky

  • Senior Member
  • ***
  • Bike: KTM 990 Adventure
    Location: Eastern Cape
  • Posts: 1,392
  • If it's not Blue with a bit of Orange it's a Lemon
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #16 on: May 22, 2011, 10:07:49 pm »
Very cool project, please keep posting, I like
" TARRED ROADS , JUST ANOTHER PERFECT EXAMPLE OF NEEDLESS,  SPENDING BY THE GOVERNMENT"
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #17 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.....


« Last Edit: May 23, 2011, 09:18:36 am by axehead »
 

Offline axehead

  • Member
  • **
  • Bike: KTM 640 Adventure
    Location: Other
  • Posts: 494
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #18 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:
 

Offline TheAnt

  • Senior Member
  • ***
  • Bike: AJS (all models)
    Location: Canada
  • Posts: 1,360
  • Thanked: 4 times
Re: 640 Adventure Project (3D Jigsaw Puzzle)
« Reply #19 on: May 23, 2011, 06:39:02 am »
Subscribed!!!  :ricky: