KTM 640 Adventure Rally Build

[WesleyDRZ400]

also a 640A owner do you know of the engine weak points?

Hey a lot was covered on first page by the dude who messaged me about engine rebuild.

However I would guess and say water pump? rocker arms? but any advice you have would be great.

I am fitting new radiator hose's as original and 23 years old, possibly fit new alloy radiators also

[WesleyDRZ400]

Just loosely fitting the tanks around 70% tight studs

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[WesleyDRZ400]

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[WesleyDRZ400]

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Very tight fit..... Basically I am out by around 5mm

Side tanks bolted via 3 bolts like a triangle shape, front and rear horizontal bolt holes on frame are out by about 5mm so as rear are in frame and front are welded luggs I will cut front luggs grind clean and reweld them. I think a angle bar will be better than luggs so once welded can drill holes exactly. Also airbox is slightly offside/non square as luggs push hard on it so angle bar less width. I also prefer to get a nut on rear rather than in the thread drilled luggs


See lugg

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I also have a few impingement areas to grind away as you can probably see in photos

[WesleyDRZ400]

It was fine before

Then I welded the gussets which reduced movement and I had to tap the subframe into the main frame luggs as before you could just pull the 4 subframe connections in by hand. Maybe it's all pulled in slightly tight

Also just as I finished up I noticed this

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That's the throttle cable caught under the main tank so the main tank is not sitting flush which In turn has caused the main take to push against the side tanks which could of caused this problem


Will sort it over the weekend

[WesleyDRZ400]

Fixed the problem of the side tanks.

Basically the main tank was not sitting fully in place, it has 2 outer rubber mounts and to inner mounts on main frame under tank center in which were obstructed

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The rear bolts fit in where the rear luggage top rack bolts to, I also drilled hole all way through as perfer to have a nut on the stud rather than in a threaded hole. Makes fitting the tanks easier as shown in photo, also the studs I'm using are just for positioning will use decent ones once finished

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I will also fit a rubber edge strip on top frame rail where the tank butts up to protect against any fretting






Fitted fairing, just sitting on as checking stud hole alignment, needs a little adjusting on the brackets but nothing to much.

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Working on the exhaust now, the pipe is 50mm OD
I have a akrapovic silencer in my garage I might try use and cut it down slightly to fit.

[WesleyDRZ400]

I think if progress stays on track by the end of next week I might be ready for a paint job.

Will sort exhaust next week so will wait until that is done as might need to weld a bracket for the silencer

I ordered adapters for the exhaust as the akrapovic silencer is a 63mm OD so I have ordered a 64mm ID to 51mm ID that will fit the 50mm OD pipe

I will need to weld the spring lug loops so I ordered a pair of them with springs.

I am thinking of a white fairing with KTM orange main tank that has white tank side guards.

New front and rear mudguards KTM orange, side rally tanks as are KTM orange.

Subframe white.

Will have to make a custom rear rack or adapt one as I used the mounting points for the side tanks. The rear rack will be white.

White rad hoses

White grips with white handguards

What you guys think?

[Richard Simpson Mark II]

Nice!

I'd consider using a Li-Ion battery for this bike.

There's a selection here

https://www.denniskirk.com/motorcycle/b ... ithium-ion

US seller, but gives you an idea of available types etc.

[Teflon Jnr]

Wicked

[Snaf MKII]

I am thinking of a white fairing with KTM orange main tank that has white tank side guards.

New front and rear mudguards KTM orange, side rally tanks as are KTM orange.

Subframe white.

Will have to make a custom rear rack or adapt one as I used the mounting points for the side tanks. The rear rack will be white.

White rad hoses

White grips with white handguards

What you guys think?

Personally I think the 640 Adventure with darker front ends look the best proportioned but then I don't ever recall seeing one as you propose so go for it.