KTM 640 Adventure Rally Build

[Snaf MKII]

It would appear the rear lights are still available from KTM and so is the main loom for the 660 Rallye at only £200.
https://www.trevorpopemotorcycles.co.uk ... ALLYE%2099

Also the headlight appears to be available for not stupid money
https://www.trevorpopemotorcycles.co.uk ... ALLYE%2099

What else can I spend your money on

Is the blue and orange seat in good condition, probably worth selling and getting something worn out to modify.

[WesleyDRZ400]

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

Agree the plan was always to cut exhaust length down, OK will look into black suede but white stitching

I understand the heated grips part, a few times in central Asia I was warming my hands on exhaust fumes. Just I don't get on with the rubber or more like plastic grips that are fitted.

[WesleyDRZ400]

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/

Yes was off one of them bikes, I think a R1

Random Ebay win at very low price as was for another project. Will cut it down and see what it looks like, worse case rethink. I liked the look of the exhausts on the link cheers.

The adaptors where only £20 so it's a low cost build on exhaust so can shelf it if it looks FUBAR

I was originally thinking a GP grammaphone style exhausts

[WesleyDRZ400]

It would appear the rear lights are still available from KTM and so is the main loom for the 660 Rallye at only £200.
https://www.trevorpopemotorcycles.co.uk ... ALLYE%2099

Also the headlight appears to be available for not stupid money
https://www.trevorpopemotorcycles.co.uk ... ALLYE%2099

What else can I spend your money on

Is the blue and orange seat in good condition, probably worth selling and getting something worn out to modify.

Yes I ordered a few parts and paid and got a email saying no longer available and money refunded.

The blue seat its worn in areas, I was going careful take it off via stables underneath and refit after using it as template. It belongs to the other Ktm 640 sitting next to this one which is next build project straight after this one as I have loads of parts.

I won that one also at a low price on ebay around £1200 and runs fine, it has the FCR Carb I might swap out and fit in this current build which is my favourite child out of the bikes I have

Then after the second Ktm 640 build we are going straight back on the near finished DRZ470 adventure build which is 90% finished, that's the wide ratio box pushing 50hp

Then it's on to the Gillera XR1 in which I found the key! Just needs starting and road registrating

I have all parts already for all these builds I collected them over the last few years, just currently it's time I don't have much off



I will put a full build cost once finished, I brought this bike cheap also I think around £1400
I have all original parts left untouched like subframe should I wish to put back how I brought it.

I am currently predicting a finished price which Includes bike purchase at £1400 and the engine rebuild at £1800 in around the £4500 figure.

I know it's just numbers but I strongly belive in bikes fit for purpose at an affordable reasonable budget or its a false economic build.

Compare this price its probably the modern day equivalent of Austin vinces DR350 25 years ago

[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/

Yes was off one of them bikes, I think a R1

They're very good quality exhausts, and expensive new as you know. Could be worse - take a look at the Aprilia RSVR Mille standard titanium can - it's bloody enormous! It's a shame, I had a racefit GSXR750 K6 stubby can you could have used, but gave it to someone else last year. They come up on ebay - something like this:

https://www.ebay.co.uk/itm/ZX10R-Racefi ... SwZ2Zertlm

[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.

[Teflon Jnr]

I love this thread and also want to live in your stable oh the fun I'd have

[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.

By fabricate I was more on the lines of adapting a battery box and fitting a securing bracket. It's pretty easier to do with a drill and grinder I think as maybe no welding needed as per the parts it's a battery box and bracket.

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I think it could be attached to the rear brake light switch backer or in that area as see ktm 660 rally location

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[WesleyDRZ400]

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/

Yes was off one of them bikes, I think a R1

They're very good quality exhausts, and expensive new as you know. Could be worse - take a look at the Aprilia RSVR Mille standard titanium can - it's bloody enormous! It's a shame, I had a racefit GSXR750 K6 stubby can you could have used, but gave it to someone else last year. They come up on ebay - something like this:

https://www.ebay.co.uk/itm/ZX10R-Racefi ... SwZ2Zertlm

Yes agree, thanks for offer if you had it. Looks a great can and that looks like ideal angle ready to fit with just a adapter connector on 50mm existing pipe

[WesleyDRZ400]

I also see a few real 1999 660 rally bikes come up for sale around the price this will cost me to build, mostly located in Germany like this, would save a lot of hassle

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