Spring and warmer temperatures are just around the corner and it is time to sort out the bike for this riding season. I have spent the whole afternoon in the garage today and got a lot done, but I ran out of electricity just before I could finish all my objectives for today.
I have quite a lot to do before I can start ridding. Through this series of posts I will be doing the following things:
-Refresh all fluids
-New filters all round
-New chain and sprockets with 15/44 gearing instead of 16/42
-Swapping clutch and brake levers
-New coolant hoses if they arrive
-Sprag clutch replacement
-New throttle tube
First on the list was finding out where the clutch is leaking. Or so I thought. I cleaned all the grime on the outside off and expected to find a half empty master cylinder, but when I loosened the bolts It was overfilled, so I guess no leaks. Next on the list was a new clutch lever. I ordered a short lever (54602031000
) because I didn’t want to cut the old ones.
Next I moved to a little something of a improvement, instead of regular maintenance. Since throttle is a little jerky on the 640 I bought a KTM Powerparts Throttle Cam system to try and tame it a little.
First order of business was removing the grip from the old tube without damage. So I pushed in a screwdriver a little and spray some WD-40 inside. Work it around and deeper in, add WD-40 and repeat. All the way to through the whole grip. and it will slide off without any damage. Make sure you degrease it before reinstalling it on the new throttle tube.
Now you can slide the rubber boot off the cables and undo the bolts keeping the throttle assembly together. Disconnect the cables and remove the old plastic tube. Once off, be sure to clean the bars thoroughly before moving on.
After securing the bars back to the bike I decided the next thing to take care is the brake fluid. I only managed to do the front as my battery that powers my lights has died, so I will be doing the rear brake in next garage sitting. This was inside the front master cylinder, not to bad.
Stay tuned for part 2.