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Author Topic: KTM640ADV Cracked sub frame repair  (Read 1706 times)

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Offline KTMRICK

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KTM640ADV Cracked sub frame repair
« 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.

 

Offline KTMRICK

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Re: KTM640ADV Cracked sub frame repair
« Reply #1 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....
 

Offline KTMRICK

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Re: KTM640ADV Cracked sub frame repair
« Reply #2 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.
 

Offline KTMRICK

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Re: KTM640ADV Cracked sub frame repair
« Reply #3 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:
 

Offline BLK

Re: KTM640ADV Cracked sub frame repair
« Reply #4 on: November 08, 2013, 02:09:23 pm »
Good to see experienced hands at work.Whos going to weld the planes now?


enjoy
 

Offline DeeCeeBee

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Re: KTM640ADV Cracked sub frame repair
« Reply #5 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?
BRP...now joined by Africa Twin Adv Sport
 

Offline KTMRICK

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Re: KTM640ADV Cracked sub frame repair
« Reply #6 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.
 

Offline KTMRICK

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Re: KTM640ADV Cracked sub frame repair
« Reply #7 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!!
 

Offline Edgar

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Re: KTM640ADV Cracked sub frame repair
« Reply #8 on: November 21, 2013, 10:04:46 am »
Daardie subframe sal nooit weer kraak nie!  :thumleft:
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #9 on: November 28, 2013, 02:49:52 pm »
Where's your welding buddy situated & do you have contact details please.
DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)
 

Offline JMG

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Re: KTM640ADV Cracked sub frame repair
« Reply #10 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
Honda XR 650L, Royal Enfield 500 classic, TVS APACHE 180, Ktm 640 adventure R, Yamaha XT250.
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #11 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.

DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)
 

Offline Firecoast

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Re: KTM640ADV Cracked sub frame repair
« Reply #12 on: February 28, 2014, 02:01:20 pm »
Pardon my ignorance, but how would you know if it is cracked?
"Don't let your ice cream melt while you're counting somebody else's sprinkles."
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #13 on: February 28, 2014, 05:05:53 pm »
Mine was obvious, as it was broken.
DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)
 

Offline JMG

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Re: KTM640ADV Cracked sub frame repair
« Reply #14 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
Honda XR 650L, Royal Enfield 500 classic, TVS APACHE 180, Ktm 640 adventure R, Yamaha XT250.
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #15 on: February 28, 2014, 06:33:24 pm »
Wayne 083 332 2527
DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)
 

Offline JMG

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Re: KTM640ADV Cracked sub frame repair
« Reply #16 on: February 28, 2014, 08:55:21 pm »
Honda XR 650L, Royal Enfield 500 classic, TVS APACHE 180, Ktm 640 adventure R, Yamaha XT250.
 

Offline Firecoast

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Re: KTM640ADV Cracked sub frame repair
« Reply #17 on: March 02, 2014, 07:14:38 pm »
Mine was obvious, as it was broken.

Thanks, that explains it so well.
"Don't let your ice cream melt while you're counting somebody else's sprinkles."
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #18 on: April 10, 2014, 07:04:09 am »
Here's what mine looked like after being put back on the bike.
DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)
 

Offline evansv

Re: KTM640ADV Cracked sub frame repair
« Reply #19 on: July 03, 2014, 04:53:19 am »
BTW Wayne also straightened, painted & pressure tested my radiators for very little money!

 
DT 125, GSX 750 ES, XJ 900, KX 125, YZ 250, WR 200, RMX 250 (280 kit), FZ-6, 2006, DT 125 LC (rear ended by Fortuner - written off), DT200R (current), KTM 625 SXC (current)