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Ktm 640adv/625smc Dakar Project Bike:

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  • Ktm 640adv/625smc Dakar Project Bike:

    this is going to be a slow project as the thumb screws have tightened & a one income family now at the moment which is fair enough considering what i have spent just on bikes in the last 10yrs



    2001 tagged/2002 engine 640ADV:
    original silver F guard in flat black but after was done in gloss black :







    but decided to fit a 07 950SE front guard onto the 640ADV. i think it will match in better with the 05/07 625SMC rear end fitted later



















    basically what it will look like







    thinking Black/White if not orange as above













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    Last edited by veetwo tls; 07-28-2010, 05:10 AM.
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  • #2
    Re: Ktm 640adv/625smc Dakar Project Bike:

    all whats needed to do the rear swap is a 05/06 KTM 625 SMC
    sub frame , rear guard & L & R air box side covers like these

    Last edited by veetwo tls; 07-28-2010, 04:46 AM.
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    • #3
      Re: Ktm 640adv/625smc Dakar Project Bike:

      basically what it will look like 640adv/625smc






      thinking Black/White if not orange as above









      Last edited by veetwo tls; 07-28-2010, 05:28 AM.
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      • #4
        Re: Ktm 640adv/625smc Dakar Project Bike:

        better do some updating

        orderd the 625SMC rear sub frame & plastics.
        silicon orange coolant hoses & blue breather hoses on the way.
        leovince X3 twin system on the way.
        Garmin nuvi 310 GPS bike kit (has SD slot) arrived.
        clutch & F brake levers arrived.
        led tail light & plate hanger arrived.


        FIRST LOT OF PARTS ON THE WAY:























        also

        this week i should have the FCR41mm carb & cables
        & hopefully the twin LEOVINCE X3 cans



        yesterday i fitted the ASI silicon coolant hoses (Orange) & breather hoses (Blue)
        it was the kit from ebay from china there cheap so thought i'd try them.
        compared to SAMCO there the same look feel etc. i had 3 problems with the kit (KTM640 Adventure) it had a U style extra hose that is not for my bike - may be for a newer model ? mine is a 2002.
        the other is i was short of a straight at 130mm long for on the water pump (i could use a samco blue hose i have spare) BUT its hidden & thought it not look right with the orange there so i didn't bother with it & the top rad cross over hose which i used a spare blue samco hose i had in my spares boxes.











        need to wait for the second lot of parts to arrive.
        subframe etc etc on order approx 6 weeks. then the rear end conversion can start.

        more pics coming as it progresses.






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        • #5
          Re: Ktm 640adv/625smc Dakar Project Bike:



          i replaced the short peace under the sensor as well with a orange off cut



          well i must say im very impressed with the leovince exhaust kits wow you get some gear with it.

          clic on all pic for BIG:

          first a pack of complementary german jelly babies







          carbon fiber hangers:




          spark arrestors & silencers:
          the 4 x optional silencers you get for each can are as

          1 x race
          1 x race with USFS Approved spark arrestor
          1 x restricted/silenced
          1 x restricted/silenced with USFS Approved spark arrestor



          wash plugs , springs , bolts etc




          the well packed 2 x cans:





          me like's my AUSPUFFANLAGEN
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          • #6
            Re: Ktm 640adv/625smc Dakar Project Bike:

            some more parts arrived 1 x 41mm FCR & Cables






            i'm still waiting for the subframe , white plastics & few other fasteners. it was out of stock at the time of order approx 6 week wait. 1st box ( orange plastics , Y pipe , air box covers & fasteners) of gear is on it's way here. the freight to oz is approx 2-3 weeks on top.
            i can't do a think really until the subframe arrives.

            so just been cleaning up sand & grit out of the electrics , fit new hoses , extended my de-comp cable by 300mm to suit the bar raisers , new inner cables in the FCR throttle cables. flush & bleed brakes , bike had engine service & suspension serviced not long ago before i bought it , fit new rear tire & anything else i can find to do on it.
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            • #7
              Re: Ktm 640adv/625smc Dakar Project Bike:

              FIRST LOT OF PARTS JUST ARRIVED:



















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              • #8
                Re: Ktm 640adv/625smc Dakar Project Bike:

                mmmmmmmmmmmmmm i like this Orange/white & graphics scheme :evil
                click on pick for BIG:
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                • #9
                  Re: Ktm 640adv/625smc Dakar Project Bike:

                  bit more done today

                  removed the 640ADV subframe - cleaned it up ready for sale later.

                  pulled the airbox & opened it up at the top & drilled 1' holes in the little side airbox cover so the FCR can breath (have a spare airbox to play with also)

                  Box 2 of parts left today have them in 3 days global express.

                  had a hickup with USPS size limitation - the subframe made the box over limit size for australian bound post. of all the country's in the world had to be australia with this.


                  but not until after doug & i almost had a heart attack on the freight
                  box was over the USPS size limit = $$$ extra in freight. wow just my luck (there was mentions of cutting the subframe to down size but we both opted out on that idea)

                  had a good laugh what doug said though
                  QUOTE: There was a line in the post office, when the clerk said, "$587.50" there was an audible gasp from everyone. Then they all looked sad when I picked up the box and walked away, they felt sorry for me. I told them, "Hey, it's ok, I will work it out"

                  Funny how when we see someone directly affected by silly government shit we feel bad, but when we can fix it by voting, most of them stay home. A fickle place this beloved land of mine.









                  anyway it's on its way
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                  Last edited by veetwo tls; 10-01-2010, 01:35 AM.
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                  • #10
                    Re: Ktm 640adv/625smc Dakar Project Bike:

                    Box 2 arrived - 4 days USPS Global Express :clap it was the cheapest for that size box my mate could find. but has been told from the supplier he can help with cheaper freight next time.
                    the supplier has offered me 20% off on any more parts & cheaper freight via going direct from him next time


                    1 x white rear plastics
                    1 x exhaust header/mid Y pipe clamp
                    1 x 625SMC sub frame

                    the sub frames are at a mates to start the welding.
                    the 625SMC subframe is to get the bolt tabs welded on for the 640 air box & battery holder + a couple support mounts.
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                    • #11
                      Re: Ktm 640adv/625smc Dakar Project Bike:

                      got my subframe back with not a thing done the guy wasted a week of my time i would had it all back together by now.
                      so tools were flying this morning & a lot of swearing.


                      so still 3 x tabs not welded on for the air box & 2 x brackets.



                      after the temper settled got busy today.

                      sorry about the shit pics but was busy wanted to get some more done.

                      usual clic pick for BIG:










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                      • #12
                        Re: Ktm 640adv/625smc Dakar Project Bike:

                        sheet of rubber matting about 3 - 4 mm thick will fill the hole for now.



                        HMmmmmmm wonder what the 950 SE plastics look like :evil


                        the gap could be fixed with a little trimming at the rear underside of the seat :evil



                        some rubber/plastic plugs should fix this :evil













                        the seat is not bolted down
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                        • #13
                          Re: Ktm 640adv/625smc Dakar Project Bike:

                          just about to wonder down the shed. i got 2 x tabs to weld on for the top back airbox mounts then all done.

                          then need to sort out the exhaust
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                          • #14
                            Re: Ktm 640adv/625smc Dakar Project Bike:

                            my most worrying part was using the new welder as i didn't have the feel of it yet. the flows are not my best but will have to do. i done the hammer test it's solid.
                            MIG would had been better than stick for bike frames. my next investment 3 in 1 (mig/stick/plasma cutter)

                            the part that caught me out was the mounts for the top/back of the battery box. i didn't have a 90 degree drill to get in between the frame cross members so i made L brackets to weld there. i used the rear mount that had to be removed from the very end of the 625SMC subframe. it had 2 nuts welded on that bracket. i just cut it in half then bent & trimmed to fit.


                            clic on pics for BIG:
                            cross support for the air box & seat mount:



                            airbox side mount:



                            Rear guard support: need drill 2 x holes & use spacers to fill the gap between the plate & guard:



                            the spacers for under the rear guard: there the rubber spacers left from the 640 top rear airbox mounts.
                            alternatively use dome head bolts & some sort of spacer.




                            next tail/brake light wire up

                            get exhaust done

                            then its a rider

                            repaint later when i grab a dakar front
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                            • #15
                              Re: Ktm 640adv/625smc Dakar Project Bike:

                              :scratch HMmmmmmm what next so not to get bored.

                              i need a 990 SUPER DUKE R to streetfighter up.
                              NOS & supercharged :evil

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