KTM 640 Adventure Rally Build

[WesleyDRZ400]

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.

Yes agree, I saw one on advrider where the guy fitted the 660 airbox and fitted one inside.

Locations for battery either In bashplate box I will make, on rear rack inside a made compartment or in airbox. I might even try fit it below the carb to airbox location at the back of the engine as it is on the 640/660 rally but would need to fab something up

[WesleyDRZ400]

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.

Yes agree it will either look real great or real sh@t

[WesleyDRZ400]

So I am waiting for the exhaust connector adaptors to arrive. I have a 50mm pipe I will cut to required size as connect.

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See the exhaust that was fitted compared to the proposed option.

I just roughly sat parts on to get a idea nothing is bolted together

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[WesleyDRZ400]

What do you guys think?

To long should I attempt to cut the can down abit or its OK.

It's just a rough idea of location as will cut the pipe with bend to fit with joint connections

The connecting pipe is long which I need to cut so if I cut the silencer down in size it will still be high up which looks better I think

[WesleyDRZ400]

What about the seat?

I'm thinking to buy some white suede material and make something swanky like this

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I could just take this seat cover off (right one) and follow the lines and cut out the sections then get professional stitched and refit

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[WesleyDRZ400]

Luggage rack ideas?

Well on sump gaurd will be a small box for basic tools small repair items.

I will be using soft luggage l, I think the side tanks will act as side racks and I can secure the soft luggage I will be using to straps like magadans use but also on the lower subframe brackets the side tanks attach to.

So I will need a rear rack..... I'm thinking something like below, I understand its not low profile and its all about weight down low but I won't be fitting anything on top just utilising the rack for the luggage rack straps to run under and be retained.

I like it that it acts as a handle should you need to man handle the bike if stuck in mud, pushing in a river crossing ect ect. Even walking around the bike with stand off can utilise it as handle.

I will offcourse need to adapt it as front brackets will need pushing out .. And spray in white to match the orange white look I'm going for

(not side racks in photo)

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[WesleyDRZ400]

Lights

Will fit some form of auxiliary light to front as good lighting is required for a adventure style bike however will keep standard headlights, as you can see the 1997 620 egs adventure has different headlights compared to 640 adventure

Ktm 640 adventure

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My 620 EGS Adventure

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Indicators..... I'm thinking to just not fit them, in UK it's fine but what about Europe ect ect...... Would it cause problems not to fit them?

Rear light..... I'm thinking old school look like original 660 rally, where can I get these lights?

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Luggage rack will be fab to fit just above as required space dictates

[WesleyDRZ400]

Recommendations for grips and handguards?

Going for white, require grips that are soft and egernomic but hard wearing and inline with bikes looks

Handgaurds tough and fit for purpose which actually fit correctly and have a larger diameter for plastic sheild for wind deflection as no heated grips will be fitted

[dibbs]

Exhaust slightly shorter, first rear rack, black suede seat and oxford heated grips! there you go ill get you started lol....

[daveuprite]

Liking this thread a lot. Great pics, ideas and engineering. I really enjoy seeing people make things when I know I would be hopeless trying to do the same. This is going to be one mean machine.

Re. the exhaust, which is the only part I feel in any way qualified to comment on having fitted hundreds of slip ons and full systems to race bikes and sports bikes... Is that really the correct can from Akra for a KTM640? It looks huge, and looks to me more like the one they used to make in the 2000s for R1s, Fireblades, GSXR1000 etc. You could cut it down, but maybe something slim and much shorter like Racefit do would suit the bike better?

https://www.speedycom.co.uk/other-perfo ... -exhausts/