The 2006 KTM 640 Adventure Build

[MuddyMudskipper]

I did a search and didn't really see any bike builds so I thought I'd let those of you who are interested in on my little orange project.:roost:

Part I: The Beginnings of the Adventure

For quite a few years I have enjoyed the outdoors and overland travel in particular. During my travels I often thought of how nice it would be to see much of what I saw from my truck on a motorcycle. It seemed to be the perfect compliment. Use my truck to pack supplies and camp out of and use the bike for day trips.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/1.jpg
Scenes like this danced in my head and I knew that I had to have a dual sport.

In the spring of 2006 the thought of buying a motorcyce moved closer to becoming a reality. The major mechanical upgrades and accessories were nearing an end for my truck so the time to search for a motorcycle began in earnest. The bike had to be a dual sport. This would give me the flexibilty of going all dirt, all pavement, or the more likely combination of both. I wanted it to be relatively light, have good aftermarket support, and not be too mechanically complicated. I looked at the bikes offered by Suzuki (http://www.suzukicycles.com/products/DRZ400SK6/Default.aspx) and Kawasaki (http://www.bikez.com/motorcycles/kawasaki_klr_650_2006.php) but the Suzuki had anemic power coupled with limited range, and the Kawasaki while robust with a strong following, was long in the tooth having gone 25 years with virtually no changes. I was uninspired by the Suzuki and Kawasaki (no offense DRZ and KiLleR owners). Honda had the XR650R (http://powersports.honda.com/motorcycles/off-road/model.asp?ModelName=XR650L&ModelYear=2007&ModelId=XR650L7) but it wasn't available in California in '06 so it wasn't an option. I looked at the V-Strom (http://www.suzukicycles.com/products/DL650AK7/Default.aspx), Caponord (http://www.powersportsnetwork.com/newvehicledetail/st=WI/VehicleCode=30738/Aprilia/Motorcycles/ETV%201000%20Caponordnewvehicles30738.htm),and Tiger (http://www.powersportsnetwork.com/newvehicledetail/st=WI/VehicleCode=24290/Triumph/Motorcycles/Tigernewvehicles24290.htm) but they were quickly dismissed because they were more of a road going bike with off road pretenstions (you too V-CapTiger owners).

My next consideration was the BMW F650 GS Dakar (http://www.powersportsnetwork.com/newvehicledetail/st=WI/VehicleCode=24265/BMW/Motorcycles/F%20650%20GS%20Dakarnewvehicles24265.htm). All ADVBimmers are synonymous with adventure biking and the Dakar was getting closer to what I was looking for, but there were two factors that were keeping me from seriously gravitating towards The Roundel offering. One was the weight. At 391lbs. excluding options and accessories the Dakar wasn't exactly svelte. The second issue was that there aren't any Bimmer Bike dealers near me, so parts and service were not something readily available. While I was aware that people travel all over the world with these things and manage to fix what's broken, my bike was to be my secondary "funship" and if anything went wrong I'd have the luxury of hauling it home to fix it. I needed to be able to easily take it to the dealer or buy parts as needed, not haul it an additional 100 miles to have it worked on or wait three to five days to have mail order parts delivered.

This led me to the offerings from KTM. Parts or service aren't an issue since there are two dealers near by. One two miles away from where I used to live and another about two miles away from where I live now (uncanny). So I looked on the KTM site and saw a few bikes that fit the bill. The first to jump at me was the 660 Rally.
http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/3.jpg
My glee was short lived as the 660 Rally was tagged with a "Not Available in the United States" statement and an MSRP of $25,000. The 660 Rally option was purged from my thought process like a hiker with Montezuma's Revenge....ummm you get the picture.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/5-1.jpg
http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/5.jpg
I'm no Marc Coma but I can pretend can't I?

Then there was the 640 Adventure. The ideal bike for what my needs were with an affordable price. However, that too had the soul crushing "Not Available in the United States" words attached to the description.....mocking me, taunting me.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/4.jpg

Okay...so my final option was the 950 Adventure (http://www.powersportsnetwork.com/enthusiasts/new_vehicle_detail.asp?VehicleCode=23407), but it wasn't exactly the ideal bike for what my needs were. It is porky, with a smaller fuel tank from the factory than the 640 so it was out. While I now love the nine-fitty, I tended to perceive it then more as a dirt Goldwing than a serious dual purpose crusher. More able to efficiently gobble up miles of black slabby stuff whose dust kicking aspriations were limited to fire roads and gravel highways (which I later rescinded...hey I was new).
http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/2.jpg

Well a month passed and I was leaning towards the Dakar again until I got a call from a friend's kid who happened to work at the KTM dealer. Apparently bikes like the 660 Rally and 640 Adventure get released mid year with the Rally going to very select dealers and the 640 shipping one each to every dealer. Needless to say I scooted right on over to the dealer to see what would be my future bike. Which I didn't actually get to see right away because it was still in a wooden crate. Anyways, a deal was struck, I watched them put my 640 together, and my butt was the first to "officially" grace the saddle for the ride home. How fortuitous for me!:wings:

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/DSCN1653.jpg

Here are the specs for those of you who are curious.

Model: KTM 640 Adventure
Year: 2006

Engine and Transmission

Displacement: 625cc (38.14 cubic inches)
Engine type: Single cylinder
Stroke: 4
Power: 53.64 HP (39.2 kW) @ 7000 RPM
Torque: 40.6 ft.lbs (55.00 Nm or 5.6 kgf-m) @ 5500 RPM
Compression: 11.7:1
Bore x stroke: 4.0 x 3.1 inches (101.0 x 78.0 mm)
Fuel system: Mikuni BST 40
Valves per cylinder: 4
Fuel control: OHC
Ignition: Kokusan DC-CDI
Starter: Electric & kick
Lubrication system: Pressure lubrication with 2 Eaton pumps
Cooling system: Liquid w/ auxiliary cooling fans
Gearbox: 5-speed
Transmission type
final drive: X-Ring Chain 5/8 x 1/4
Clutch: Hydraulic Magura wet multi-disc clutch

Physical Measurements

Dry weight: 348.3 pounds (158.0 kg)
Seat height: 37.2 inches (945 mm)
Overall width: 25.2 inches (640 mm)
Ground clearance: 12.4 inches (315 mm)
Wheelbase: 59.4 inches (1,510 mm)

Chassis and Dimensions

Frame type: Chromoly steel, powder-coated
Rake (fork angle): 27.5°
Trail: 4.9 inches (124 mm)
Front suspension: WP-USD 48 mm
Front suspension travel: 11.8 inches (300 mm)
Rear suspension: WP – Monoshock
Rear suspension travel: 13.2 inches (335 mm)
Front tire dimensions: 90/90-21 Metzler Enduro 3 (60/40)
Rear tire dimensions: 140/80-18 Metzler Enduro 3 (60/40)
Front brakes: Brembo Double disc
Front brakes diameter: 300 mm (11.8 inches)
Rear brakes: Brembo Single disc
Rear brakes diameter: 220 mm (8.7 inches)
Exhaust system: Supertrapp HGS 4 Stainless

It's late, I'm sleepy. I will work on Part II tomorrow.

[HiLift Jack]

This is a crated 2006, if so sweet deal.

[MuddyMudskipper]

This is a crated 2006, if so sweet deal.

It was still in the box when I got it.

[Scott Brady]

Have you spent much time on the trail with it yet? What is the overall feel?

[ShearPin]

Hey congrats - I am looking forward to posts on this build. Over the years I've found the urge get myself a bike hard to shake. I figure it is inevitable that one day I'll pick one up.

Always liked the 640.....

Henry

[Kermit]

Scott,

It almost feels like a snowmobile at first, mainly because of the huge fairing. Surprisingly flickable once you get used to the weight. Point and shoot type bike. Wasn't too bad on the street either. Motor has plenty of torque to loft the front end over objects, very easy to ride wheelies.

I only had 2 days on one...reluctant to give it back. ;)

[wesel123]

Have you spent much time on the trail with it yet? What is the overall feel?


First off Muddy I aint knocking your bike, this is just another opinon.

Scott,

I just sold mine a few weeks ago. Super fun in the dirt, but not as much fun as my 450EXC. You are really at the mercy of 7 gallons of gas. I totally felt like Cyril Despres going flat out in the California Desert, in the tight stuff its a bit to handle, but fun non the less.

On the street what a differnt story, WAY to buzzy. Dont get me wrong in the twisites it a blast to ride but long stretches of hwy are no buano (Trust me I tried every single anti-vibration trick in the book, Liquid bar snake, filled the swing arm with foam, gel grips, re-blanced the tires anfet every ride non of it worked). I had a week tripped planned with my best friend (whom has a 950 adv) 200 miles in I turned around. I couldn't take it anymore. Now I may be a wuss but Ive been riding for a long time and I wanted nothing more than to get off that bike.

I bought a 2008 KLR for my motorcyle expedtions and will keep the nasty stuff for my 450. Ive taken the KLR all the same places ive taken the 640, not as fast, but I still got there.

Just food for thought.

Again Muddy RIDE THE HECK OUT OF THAT BIKE!!!!!!!!

[Kermit]

They do buzz a bit, it didn't bother me at all, maybe because I have a 2-stoke 300 for the nasty stuff. I have also ridden solid mount, hard tail choppers too, for hundreds of miles. Now those things will rattle your Jacobs right off.

[flux]

I'll be following this thread for sure. I ride an 02 LC4E which is 'offroadier' than the Adventure...carries less fuel, no fairings. As a matter of fact I'll soon be parting out an 01 E model so keep your eyes peeled.

I love mine...sure, it vibrates but there are ways around it. Get that sucker jetted properly, put some good grips on, and get some good boot inserts to take away the vibe from the feet. My inserts are called 'happy feet' or something stupid and was the best $40 I have ever spent. It's a thumper...it's gonna vibrate.

So, curious, what are you 'building' this bike into? A rally bike?

[MuddyMudskipper]

Have you spent much time on the trail with it yet? What is the overall feel?

I have hit the trail with the bike and while the tank and fairing make it feel big, it really isn't. With enough seat time the bike will start to shrink. The only real knock I have for the bike is that it isn't for the short of inseam. The seat height can be daunting and with the full complement of bags it might be a bit too much to mount or dismount. Emig (http://www.emigracing.com/) and Kouba (http://www.koubalink.com/KTM.html) make lowering links for the 640 but that's a whole other topic. ;)


Scott,

It almost feels like a snowmobile at first, mainly because of the huge fairing. Surprisingly flickable once you get used to the weight. Point and shoot type bike. Wasn't too bad on the street either. Motor has plenty of torque to loft the front end over objects, very easy to ride wheelies.
:iagree:

[MuddyMudskipper]

First off Muddy I aint knocking your bike, this is just another opinon.

No worries!


I looked at the bikes offered by Suzuki and Kawasaki but the Suzuki had anemic power coupled with limited range, and the Kawasaki while robust with a strong following, it was long in the tooth having gone 25 years with virtually no changes. I was uninspired by the Suzuki and Kawasaki (no offense DRZ and KiLleR owners).

See above.:shakin: Seriously, the 2008 KLR is THE improvement of the century for fans of the venerable KLR. Honestly, if that bike were offered in 2006 my choice in bikes may not have been the same.



Scott,

I just sold mine a few weeks ago. Super fun in the dirt, but not as much fun as my 450EXC. You are really at the mercy of 7 gallons of gas. I totally felt like Cyril Despres going flat out in the California Desert, in the tight stuff its a bit to handle, but fun non the less.

On the street what a differnt story, WAY to buzzy. Dont get me wrong in the twisites it a blast to ride but long stretches of hwy are no buano (Trust me I tried every single anti-vibration trick in the book, Liquid bar snake, filled the swing arm with foam, gel grips, re-blanced the tires anfet every ride non of it worked). I had a week tripped planned with my best friend (whom has a 950 adv) 200 miles in I turned around. I couldn't take it anymore. Now I may be a wuss but Ive been riding for a long time and I wanted nothing more than to get off that bike.

I bought a 2008 KLR for my motorcyle expedtions and will keep the nasty stuff for my 450. Ive taken the KLR all the same places ive taken the 640, not as fast, but I still got there.

I agree to an extent. Yes the 640 is not the hardcore dirt weapon the 450 EXC-G (http://www.powersportsnetwork.com/newvehicledetail/st=WI/VehicleCode=38734/KTM/Motorcycles/450%20EXC-G%20Racingnewvehicles38734.htm) or 525 EXC-G (http://www.powersportsnetwork.com/newvehicledetail/st=WI/VehicleCode=38732/KTM/Motorcycles/525%20EXC-G%20Racingnewvehicles38732.htm) are but those are race bikes with signals and mirrors. The hi-cap fuel tank is either a detriment or an asset, depending upon what your intentions are. From what I've read the 450 and 525 EXC-G bikes are definitely not suited for the long haul in the way the the adventure bikes are. This is a fact I'm sure the suits at KTM were keenly aware of when they released the model line up.

As I mentioned in my first post, the 640 exactly fit what my criteria was. Road capable, off-road capable (not necessarily hardcore MX), relatively light, can haul gear, and easily transported on the back of my rig. IMO the 640 was the best performing on and off-road adventure bike of the '06 crop that combined all of my needs.

Additionally, at the time I also had a 450 Banshee, my Rover, my daily driver beatermobile, my '68 Cougar, and a whole bunch of gear and miscellaneous items to store. I couldn't really afford the real estate in the garage for multiple bikes.


Again Muddy RIDE THE HECK OUT OF THAT BIKE!!!!!!!!

THANKS! You can't go wrong with the '08 KLR and 450 EXC...ENJOY!!!!

[MuddyMudskipper]

Hey congrats - I am looking forward to posts on this build. Over the years I've found the urge get myself a bike hard to shake. I figure it is inevitable that one day I'll pick one up.

Always liked the 640.....

Henry

They're great bikes and thanks for stopping by!:wings:

[MuddyMudskipper]

I'll be following this thread for sure. I ride an 02 LC4E which is 'offroadier' than the Adventure...carries less fuel, no fairings. As a matter of fact I'll soon be parting out an 01 E model so keep your eyes peeled.

Awesome, and thanks for checking this thread out. Funny you should mention the LC4. My friend's old boss gave him one with a blown motor for helping him modify his TRD Tacoma. Theoretically with some horse-trading I could give the 'ole 640 an "offroadier" makeover if I felt like it...but I won't for now. I kinda dig the range.


I love mine...sure, it vibrates but there are ways around it. Get that sucker jetted properly, put some good grips on, and get some good boot inserts to take away the vibe from the feet. My inserts are called 'happy feet' or something stupid and was the best $40 I have ever spent. It's a thumper...it's gonna vibrate.

Mine runs great and I never really noticed the buziness but I think its because I knew what to expect with a thumper, especially the LC4. At least the motors don't rattle themselves apart like they did in the '01 and older LC4's.


So, curious, what are you 'building' this bike into? A rally bike?

Maybe build was the wrong word since I am not building it from scratch, doing a rally conversion, or turning it into a chopper (http://www.fmfracing.com/company/pressroom.aspx?id=137). It's more of a modification thread I guess.

Use my truck to camp out of and the bike to explore with. This thread will cover the implementation of modifications that I see fit to make it a good ADV bike for my needs.

[HMR]

Nice bike!

I was leaning towards the '06 640 after I got rid of my '05 950. I bought a 1200GS and now I get smoked everytime I ride with my buddy who's on my old 950. Maybe I should've went with the 640...

Aargh!!! Why do there have to be so many great bikes?!!!


:roost:

[MuddyMudskipper]

Nice bike!

Thanks!


I was leaning towards the '06 640 after I got rid of my '05 950. I bought a 1200GS and now I get smoked everytime I ride with my buddy who's on my old 950. Maybe I should've went with the 640...

:hehe: :hehe: Perhaps you should have. Why'd you switch?


[Aargh!!! Why do there have to be so many great bikes?!!!
:roost:

Probably to drive us nuts. The street stuff is a WHOLE different story. If I had my druthers I'd own sooooo many vehicles.

[Kermit]

Probably to drive us nuts. The street stuff is a WHOLE different story. If I had my druthers I'd own sooooo many vehicles.

My list is loooong....come on Lottery!....many jobs at hand, many right tools for the jobs...;)

I don't know how many KTM owners are on here, but, I get posters from them showing me all of their bikes and specs. I put it up on a wall and circle the ones I want....maybe Santa, will drop a couple off next year.

[MuddyMudskipper]

Kinda pissed right now. I was working on Part II and decided to take a small detour and look at steering dampers. Windows shut down because it couldn't load a picture on the Scott's site.:eek:

Tomorrow's another day.:(

[FourByLand]

Very nice bike Richard!

I am curious to see what it looks like with the cases attached...

Looking forward to part 2!

:rockon:

[Kermit]

Kinda pissed right now. I was working on Part II and decided to take a small detour and look at steering dampers. Windows shut down because it couldn't load a picture on the Scott's site.:eek:

Tomorrow's another day.:(


I run a Scotts, had it for 5 years, I swap it from bike to bike. High and low speed dampening, plus you can adjust the sweep. What part of the steering arc where you need the most or littlest dampening.

http://inlinethumb34.webshots.com/19425/2077895720093498191S425x425Q85.jpg (http://good-times.webshots.com/photo/2077895720093498191ksxWCX)

You may want to check RTT, they are incorporated into the top triple clamp, then has a remote lever to adjust the dampening, great set up, the only thing, since it is bike specific, you can't swap it bike to bike. (easily)

http://www.eatmydirt.com.au/images/news/product/rtt/clamp1.jpg

[flux]

Yeah, the engine won't vibrate apart, but I have had my bash plate about vibrate itself off...luckily we caught it in time...was hanging on by one bolt!!! My advice is to carry some loctite in your kit.

I have a Scotts damper and love it. I know it has saved my @$$ more than once.

[MuddyMudskipper]

Very nice bike Richard!

I am curious to see what it looks like with the cases attached...

Looking forward to part 2!

:rockon:

You'll probably see it before anyone else does.:shakin:

[MuddyMudskipper]

Yeah the Scott's parts seem to be the damper of choice for all of my MX buddies. The one thing that I really don't like is going through soft sand when I'm riding. I do believe in the "lean back and pin it" philosophy of riding in sand but it just feels so wobbly and funky. Anyways from what I've been told is that the steering damper will not only make overall riding a little less work, it will make the bike a whole lot less work in tha sand.

I have had friends offer to let me ride their bikes to see the difference but I really don't like to ride other people's stuff.

[Kermit]

It does help quite a bit in sand...rocks especially. But, proper suspension setup is the starting point, then ad a stabilizer to enhance it even further.

Sand is best to be "surfed".

I forget the stabilizer is even there...only when I pull it off, I notice the difference.

GPR's are nice too.

[MuddyMudskipper]

It does help quite a bit in sand...rocks especially. But, proper suspension setup is the starting point, then ad a stabilizer to enhance it even further.

Sand is best to be "surfed".

I forget the stabilizer is even there...only when I pull it off, I notice the difference.

GPR's are nice too.

That's what I hear.

[MuddyMudskipper]

Part II: Cheap and Easy

Like the title says, this is where I’m going to cover the basic cheap and easy modifications I have made to the 640 thusfar.

Footpegs

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/8.jpg

I took the rubber foot pads off of the footpegs so I can get a better grip with my boots. My guess is that they are there for comfort and vibration but I would hate to have them on there in any kind of rain, mud, or snow.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/9.jpg

The pads were held on by a 10mm self locking nut.

Headlight Protection

The next modification I did was but the Touratech headlight protector. It’s a complete kit that doesn’t require any drilling and only hand tools. I had looked at other alternatives from Cycleventure (http://www.cycleventure.com/products/light_guard/index.htm) or the clear rubber light protector that you stick on. I didn't choose these since once water and mud got behind them they couldn't be easily cleaned (especially on the go).

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/7.jpg

IMO they look kind of silly like Elvis glasses but for $49 it has to be cheaper than replacing the DE headlight assembly on the 640.

Touratech Headlight Protector Part Number: 040-0382 (http://www.touratech-usa.com/shop/show.lasso?sku=040-0382&-session=touratech:476C463C02b0023870vpj42F8F80)

Handlebars and Grips

Next up were the handlebars. The 640 came with the Magura X-Line bars from the factory which were kind of low for my taste. Rather than add bar risers I went with the slightly taller Renthal Fatbar. I also swapped the factory grips for a pair of Renthal Full-Waffle Single Compound soft grips.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/30.jpg

KTM Part Number: U6951.392 (http://www.ktmcyclehutt.com/ktmstore/hardparts/handle_bars.htm)
Renthal Part Number: 608-01OR (http://www.renthal.com/fatbar.asp)
Grips: GO92 (http://www.renthal.com/grips.asp)

Throttle Side Mirror Relocate

The Right mirror on many of the KTM bikes are installed onto the handlebar via an integrated mount on the brake fluid reservoir.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/4060497-M.jpg

This does save bar space but it can be a problem in the event you crash. I have heard stories of the mount breaking so bad it cracks the reservoir causing fluid to leak rendering the brakes inoperable. Not fun if you’re in the middle of nowhere.

Rather than wait for this to happen I decided to relocate the mirror using the mount for a Duke II. About $8 for the mount and way cheaper than replacing a busted reservoir.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/32.jpg

I wanted to clean the look of the reservoir up so I cut the OE mounting hole off with a cut off wheel, smoothed the cut with a file and some sand paper, and painted it.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/31.jpg

Duke II Mirror Mount Part Number: 580.12.040.050

Here's the whole set-up with the bars, grips and mirror relocate.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/33.jpg

Joe Hauler

Not a bike mod, not a truck mod.

Joe Hauler Review (http://expeditionportal.com/forum/showpost.php?p=220174&postcount=17)

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/DSCN3767-1.jpg

That's all for the cheap and easy stuff. I'll keep Part II updated as more cheap and easy modifications materialize.

[flux]

The thing with sand riding is that you simply can't go slow. Forget first gear even exists. Forget your front brake exists while you're at it. If you can keep it in 2nd and even 3rd gear you'll be going quick enough to stay on top of the sand...lower speeds you'll just sink, front tire first, and down you go. Like Kermit said, you have to 'surf' it. That is a good description. Hold the bars firm yet loose if that makes sense, lean back, and control steering with your knees and hips. At least, that's my method and I'm sticking to it. I only ride sand like twice a year when we head to Ocala but I love it every time.

As for dampers...have you guys seen a few new bikes are starting to come with them stock. One of the new Honda dirtbikes (a CRF I think) and even the new Suzuki B King come with them...funky looking dampers, too.

[flux]

Those orange bars really pop!

[MuddyMudskipper]

Those orange bars really pop!

Funny you should mention that. I was actually wanting the black bars which you can get if you use the Renthal part number. The dealer only had the KTM part number which happen to only come in orange. Not my first choice but whatever, they're more comfy than the Magura bars.

[Kermit]

I only ride sand like twice a year when we head to Ocala but I love it every time.

.

I wish that was the case, every trail in AZ has a "bit" of sand in it...I get lotsa practice. While you don't have to WOT, it sure does help.

A "little" sand...:D http://good-times.webshots.com/video/3091689380093498191

Muddy, these help with vibration too. They're a little too fat for my taste. I like half waffles...hey everyone is different.

I am sure you have paid a visit or two to KTMTalk...loads of info on there.

http://www.the-larkins.com/5-13-03a%20012.jpg

My mirrors...sure, they are "legal"...I am a less is more kinda guy...they work sorta.

http://inlinethumb26.webshots.com/217/2489049470093498191S425x425Q85.jpg (http://good-times.webshots.com/photo/2489049470093498191StQUTu)

[MuddyMudskipper]

I wish that was the case, every trail in AZ has a "bit" of sand in it...I get lotsa practice. While you don't have to WOT, it sure does help.

A "little" sand...:D http://good-times.webshots.com/video/3091689380093498191

Where I live every trail has a little sand in it too so I can practice whenever I want.


Muddy, these help with vibration too. They're a little too fat for my taste. I like half waffles...hey everyone is different.

Sweet. I have big hands so I when the Renthals I have go away I'll give them a try.


I am sure you have paid a visit or two to KTMTalk...loads of info on there.

I have been there but I don't go visit there as often as I visit ExPo, LRRForums, VWVortex, D-Web, or ADVRider. I tried registering once but you can't with a free email address so I never bothered again.


My mirrors...sure, they are "legal"...I am a less is more kinda guy...they work sorta.

http://inlinethumb26.webshots.com/217/2489049470093498191S425x425Q85.jpg (http://good-times.webshots.com/photo/2489049470093498191StQUTu)

Nice. I would like to use smaller mirrors for mine but until I find something I really like I'll keep the Mickey Mouse ears. Duke mirrors perhaps?

[Kermit]

I had the same problem with KTMTalk, with the free e-mail thing. I e-mailed them personally, and they let me in. If you still have problems, let me know. I can talk to one of the Admins....it really is a wealth of information.

I am on ADV Rider too, I just don't post very much...almost too many people on there. I just read the ride reports and day dream.


Yeah, those mirrors are just enough to keep my 300 street legal. I like keeping that bike lean. They don't really work, just enough not to get a ticket.

Even with big mirrors they vibrate so much offroad, they are worthless.

[MuddyMudskipper]

I had the same problem with KTMTalk, with the free e-mail thing. I e-mailed them personally, and they let me in. If you still have problems, let me know. I can talk to one of the Admins....it really is a wealth of information.

I just sent an email off to Admin to plead my case. I'll keep you posted.


I am on ADV Rider too, I just don't post very much...almost too many people on there. I just read the ride reports and day dream.

That's pretty much what I do. That board is so MASSIVE it is easy to get lost in just one thread.
I thought I recognized your name.


Yeah, those mirrors are just enough to keep my 300 street legal. I like keeping that bike lean. They don't really work, just enough not to get a ticket.

Even with big mirrors they vibrate so much offroad, they are worthless.

My big mirrors suck. I get a great view of each of my shoulders. I'm not sure you'd get away with those out here.

[Kermit]

That's pretty much what I do. That board is so MASSIVE it is easy to get lost in just one thread.
I though I recognized your name.
.

I am "Kermit13" on ADV Rider, "Kermit" on KTM Talk.

[flux]

I post on ADV...mostly in the "East" forum under DOG- Dualsporters Of Georgia. We have a good gang there. I had to leave ADV once just b/c I couldn't be around all the negativity that hangs around in there. I am really just a sensitive artist! :sombrero:

We did a nice loop locally yesterday...one thing I need to add to my bike are some risers. I also got to ride a Husky TE610...sure would be nice to have that 6th gear!

Have you guys ever tried the dual-star mirrors that mount directly on the handlebar? They don't have a stalk...I used them on my 525 EXC and liked them...took awhile to get used to looking under your arm but they actually work pretty good (all I use mirrors for is looking for my riding buddies' lights to make sure they are still there, and for watching for cops!) so vibrations aren't that big a deal to me.

As for grips... I would like to try out these new Pro Taper pillowtop grips...they look great.

[flux]

Here's a pic I took yesterday of what we affectionately call the "First Section." It is 5 minutes from my house. When it rains, this place becomes and ultra slick mud hole filled to the brim with red GA clay. This hill in the background was fun to come down...can you say 'fishtail?' ;) Last time we were here, there were some truck guys trying their damndest to get up it...it was prett amazing actually.

Sorry if this is too big, I do not know how to shrink the sizes.
http://img.photobucket.com/albums/v226/flux_capacitor/Troy001.jpg

[Kermit]

This will help fuel slosh in that big 7 gallon tank.

http://www.weaponmx.com/shop/weaponmx/productdetail?p=15

http://www.weaponmx.com/upload/images/TankFoamAd1.jpg

Flux...I have never run those type of mirrors, will have to check them out. The ProTaper pillow grips look cool too. http://www.ktmcyclehutt.com/ktmstore/2008_protaper/pro_pillow.jpg

I may try those new Kevlar Renthals too.

http://www.offroadworld.co.uk/uploads/images_products/413.gif

[MuddyMudskipper]

This will help fuel slosh in that big 7 gallon tank.

Hmmmm....that's similar to what road and drag racers use in their fuel cells to reduce weight transfer. I wonder if it breaks down or how it affects the fuel guage?


Flux...I have never run those type of mirrors, will have to check them out.

Depending on which Dual-Stars you use I've heard they tend to fall apart on a "buzzy" bike.

I might try these mirrors (http://www.ktmtwins.com/950adventure/58312040200.html).

They have some good ideas for mirrors over here (http://www.advrider.com/forums/showthread.php?t=276386&highlight=dual+star+mirrors).


The ProTaper pillow grips look cool too. http://www.ktmcyclehutt.com/ktmstore/2008_protaper/pro_pillow.jpg

Those look comfy.

[Kermit]

I wonder if it breaks down or how it affects the fuel guage?

.

I don't know, it has been getting great reviews in the moto magazines.

I am putting on a 5.8 gallon tank on my 300, for Baja in March, I may try that foam...it's only $50.

[flux]

Muddy, my bud has those folding KTM mirrors on his Super Enduro...they are very nice but I think one crash will destroy them...just my opinion. Really when you get down to it, you have to look at mirrors as expendable.

[FourByLand]

Looks sexy with the hard cases!

When do you think you will paint the plastics?

:Astrologist:

[RHINO]

great thread ! i really miss my 03 640 adv. i ran duke mirrors.

[TxRider]

If your looking at at a 640 for just poking around that huge 7 gallon tank is a bit big.

You might want to look around for a 625SXC. I love mine for a lightweight DS machine.

You can drop a factory 5 gallon tank on it for about a 200 mile range. Lighter and easier to deal with, but the U.S. models aren't street legal so you have to add lights, fortunately the euro version is street legal so the factory parts to do it are easy to order and plug in.

Or maybe even a 625 SMC.

If I was just hauling one around on my truck for a little exploring from camp though I'd probably just stick with a little 250cc dual sport. To me a 600 class or bigger means the bike is big enough to go without the truck. :)

[TxRider]

If your looking at at a 640 for just poking around that huge 7 gallon tank is a bit big.

You might want to look around for a 625SXC. I love mine for a lightweight DS machine.

You can drop a factory 5 gallon tank on it for about a 200 mile range. Lighter and easier to deal with, but the U.S. models aren't street legal so you have to add lights, fortunately the euro version is street legal so the factory parts to do it are easy to order and plug in.

Or maybe even a 625 SMC.

Then again, now that KTM has ended the LC4 engine line and is coming out with a whole new 600 class bike redesigned from the ground up maybe waiting a year or two might be best.

If I was just hauling one around on my truck for a little exploring from camp though I'd probably just stick with a little 250cc dual sport. To me a 600 class or bigger means the bike is big enough to go without the truck. :)

[MuddyMudskipper]

great thread ! i really miss my 03 640 adv. i ran duke mirrors.

Thanks! It is a great bike.

[MuddyMudskipper]

If your looking at at a 640 for just poking around that huge 7 gallon tank is a bit big.

You might want to look around for a 625SXC. I love mine for a lightweight DS machine.

You can drop a factory 5 gallon tank on it for about a 200 mile range. Lighter and easier to deal with, but the U.S. models aren't street legal so you have to add lights, fortunately the euro version is street legal so the factory parts to do it are easy to order and plug in.

Or maybe even a 625 SMC.

Then again, now that KTM has ended the LC4 engine line and is coming out with a whole new 600 class bike redesigned from the ground up maybe waiting a year or two might be best.

If I was just hauling one around on my truck for a little exploring from camp though I'd probably just stick with a little 250cc dual sport. To me a 600 class or bigger means the bike is big enough to go without the truck. :)

The bike and its big tank have served me very well. Especially in places where fuel is a bit sparse. I took it to DV last year and where the DRZ400 was running dry I kept going.

You are right in that the bike is big enough to go without the truck but it is small enough to go with the truck as well. Having a bike like this gives me options for the short, medium, and long hauls. For the trips I do bring the bike with me it isn't merely used for poking around the campsite. Heck I could use a TW200 for that.

[flux]

Then again, now that KTM has ended the LC4 engine line and is coming out with a whole new 600 class bike redesigned from the ground up maybe waiting a year or two might be best.



That is not entirely true...the new 690's are LC4 engines. I have ridden the 690SM and it is SMOOOOOTH.... My 640 is a paint shaker, but I love it so!

[MuddyMudskipper]

Part III: Exhaust

The 640 comes with a 50 State compliant exhaust system manufactured by SuperTrapp. It is a decent exhaust but it is heavy and very restrictive with all of the associated emissions equipment. The power of the bike was also a little flat in my opinion and after doing a little research I was able to determine that changing the silencer and re-jetting the bike would "liven" the bike up a bit.

When I brought my bike in for the first service to the dealer I inquired about exhaust for my bike. Coincidentally the dealer had just installed an Akrapovic titanium slip-on exhaust and a re-jet on another customer's bike and highly recommended the same set-up. I had the dealer order the parts up and do the work since the 640 was in the shop anyways. I am very pleased with the exhaust and jetting mods that were done to my bike.

The Akrapovic

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/11.gif

The The Akrapovic silencer is a very nice part and 60%, or about five pounds lighter than the factory SuperTrapp. The Akrapovic also has a removable silencer for when you want to wake the neighbors.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/12.jpg

According to the db test on ADV Rider (http://www.advrider.com/forums/showthread.php?t=65420) the stock SuperTrapp exhaust tests at 90db @ 4250 RPM and 96db @ 6000 RPM. The Akrapovic tests at 98db @ 4250 and 102db @ 6000 RPM. For reference, the Hella Super Tone Dual horns belt out and advertised 118 db’s. Without the silencer the bike is LOUD under load but quiet (enough) when you’re just cruising.

The SuperTrapp

The rangers and police have left me alone because the 640 isn’t a dirt only bike and I doubt they’d notice any of the emissions stuff missing. I did keep the factory SuperTrapp for the places where I know the rangers will check for spark arrestors and db since it is very easy to swap the exhaust pipes out.

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/13.jpg

http://i110.photobucket.com/albums/n100/mrburns71/640%20Adventure%20Build/14.jpg

Akrapovic LC4 Titanium Slip-on Exhaust Part Number: 57305079400 (http://ktmcyclehutt.com/ktmstore/hardparts/pipes_silencers_exhausts/ktm_factory_pipes_4stroke.htm)