KTM 640 Adventure Rally Build

[bikenav]

hello your engine summary includes far more info than I know about, but a couple of tips anyway, my 640A headlamps are very heavy units and give off a pathetic amount of light I would avoid these or at least bare that in mind, the sprag apparently is quite reliable but change its spring occasionally nick one off a decent quality lip seal, the bottom spherical bearing on my rear damper unit is a KTM special and now obsolete, the skinny suspension links on my bike were very heavily corroded from the inside and ready to blow from the inside, I guess yours has a cable clutch as the same is still true today KTM's slave cylinders are a joke of reliability, yes I use oil, oberon fix's it. These things are loud I have both the alloy lighter noisier can and the heavy steel one there is a distinct performance gap but the loud one gets on my tits on a long day or trip. Keep up the story like what your doing and enthusiasm.

[WesleyDRZ400]

hello your engine summary includes far more info than I know about, but a couple of tips anyway, my 640A headlamps are very heavy units and give off a pathetic amount of light I would avoid these or at least bare that in mind, the sprag apparently is quite reliable but change its spring occasionally nick one off a decent quality lip seal, the bottom spherical bearing on my rear damper unit is a KTM special and now obsolete, the skinny suspension links on my bike were very heavily corroded from the inside and ready to blow from the inside, I guess yours has a cable clutch as the same is still true today KTM's slave cylinders are a joke of reliability, yes I use oil, oberon fix's it. These things are loud I have both the alloy lighter noisier can and the heavy steel one there is a distinct performance gap but the loud one gets on my tits on a long day or trip. Keep up the story like what your doing and enthusiasm.

Hi the engine summary was not my info it was what a expert on this bike informed me about. He knows his stuff so took his advice.

Yes it's a cable clutch, I'm Planning on changing the levers. I have the zeta folding levers on my drz which I much prefer so will look into a suitable type. Understand about Can, on my drz I had the preferred MRD SSW for 470 kits and it was offensively loud. I have a dB killer for the can I will try out and it's road legal stamped which I think is needed as I read in Europe its a thing cops look for if they pull you over

[WesleyDRZ400]

Great build, you are obviously very skilled.
If you do decide to locate the battery by the carb and fab a mounting bracket up, if you could make 2 and I'd buy one from you that would be great.

I just checked tonight, can bolt off the rear brake switch bracket hole on the right side and helmet lock(I'm removing) bracket hole on the left side. Will need slightly smaller battery also.

[bowber]

Looking good so far, the later 640s were a good base bike, I never liked the look of the Adventure but it served a purpose and did it well.
I'm also thinking the Akra is too long, can you shorten the link pipe rather than the can? That'll help keep your ears from bleeding on a long day.

Steve

[Wonkyconk]

Great build, you are obviously very skilled.
If you do decide to locate the battery by the carb and fab a mounting bracket up, if you could make 2 and I'd buy one from you that would be great.

I just checked tonight, can bolt off the rear brake switch bracket hole on the right side and helmet lock(I'm removing) bracket hole on the left side. Will need slightly smaller battery also.

I'll have a look and see what I can come up with.
Keep the posts coming, it's a great build.

[WesleyDRZ400]

Looking good so far, the later 640s were a good base bike, I never liked the look of the Adventure but it served a purpose and did it well.
I'm also thinking the Akra is too long, can you shorten the link pipe rather than the can? That'll help keep your ears from bleeding on a long day.

Steve

Gone with plan B, the akrapovic adapter was to large and short, I had this in the garage so will fit it on. I will weld a bracket from frame to hold bracket on Can.

It is a unknown make no stamps, think best to fit something and get it on the road and at a later date once all teething problems getting ironed out will ride it to a exhaust builder to fab up a link pipe to a better end can I will supply like the ones mentioned on previous posts.

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[IanB]

I fitted one of these to my 640 Enduro

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Coupled with a FCR 39 Flat Sided Carb, transformed the off road performance

[WesleyDRZ400]

I fitted one of these to my 640 Enduro

KTM02Silencer (Small)[1].JPG

IMG_0655.JPG

Coupled with a FCR 39 Flat Sided Carb, transformed the off road performance

Yes I looked at 640 cans but they are left sided and my pipes right sided, would have been ideal as actual design for the bike.

[WesleyDRZ400]

I could cut it down also, loss about 30% in length

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[IanB]

I fitted one of these to my 640 Enduro

KTM02Silencer (Small)[1].JPG

IMG_0655.JPG

Coupled with a FCR 39 Flat Sided Carb, transformed the off road performance

Yes I looked at 640 cans but they are left sided and my pipes right sided, would have been ideal as actual design for the bike.

Would fitting the 640 Enduro front pipes take the exhaust across to the left hand side and allow the L/H silencer fit ?