Harry's 660Z...
 

Allright, have a look at mine? I will not start with pics of how it was originally, as anyone knows what an original Ten looks like :nana:

Instead, i will pick up the story a few mods later on, when i fitted Kevs O2 mod, a fuel mod, Aluminium Yamaha engine guard- already replaced by a Touratech Small, MTC single can, and already done my tail-tidy...

http://i62.tinypic.com/2niw3eu.jpg

http://i60.tinypic.com/1zf4mqu.jpg

http://i61.tinypic.com/1sxxeu.jpg

http://i61.tinypic.com/2hzu9tc.jpg

Making a KTM front end fit:

http://i59.tinypic.com/vx17ja.jpg

Machined a ring to fit in the lower tri-clamp, supporting the lower bearing

http://i58.tinypic.com/indamh.jpg

And milled out the chamber to fit the Yamaha pin:

http://i60.tinypic.com/2wp55w2.jpg

Then machined a fitting spindle as an aid to determine the position of the steering-stoppers:

http://i62.tinypic.com/es7toh.jpg

And one front fork done, now just mount and revise/adjust on the bike by a specialist:

http://i61.tinypic.com/qybthk.jpg

Meanwhile i took a critical look at the dB-killer in the MTC can, after reading reports of people losing it underway... That is a crap indeed and just waits to give way to the pulses from the big single. MIG-Spotwelded only... And the bend at one place to make the bolt fit in also is very sensitive to metal-fatigue.

http://i60.tinypic.com/dca0cz.jpg

http://i62.tinypic.com/15ft6cn.jpg

http://i60.tinypic.com/2ls20j.jpg

http://i58.tinypic.com/34qsfti.jpg

So what i did was flowing the existing welds with TIG, so that they would melt out and hold at bigger surfaces, instead of just laying on top of the metal.
Also i milled a ring that carries in the whole inner diameter of the exhaust outlet-pipe. This came in place of the bent part where the locking bolt goes and i welded it through all around. That way hopefully the dB-killer cannot vibrate anymore. Also stops leaking along the sides, making the sound a tick less loud and even a bit fuller.

http://i60.tinypic.com/2e167ls.jpg

After fitting the tail tidy and the exhaust, it was time to close the gap in the inner rear fender. A small piece of a tiny conveyor belt did the trick:

http://i60.tinypic.com/j5z4pl.jpg

http://i62.tinypic.com/1h4kn7.jpg

And what to say about my seat? Got new polstering with a layer of cell-foam, wild leather surface and got a bit higher and much spacier. It should now be a great compromise between long, long travels and also offroad- and rally usage, which are two worlds wide apart. Will report on that after my holiday, then i will know for sure. First test rides proved a massive improvement already though, really comfortable yet reasonably hard and adapting itself to the body. Raymond, thanks for this perfect piece of work!

http://i58.tinypic.com/33nkpvn.jpg

Looks good!! :041::041:

Thanks! More to come as the front fork is mounted, professionally revised, and adjusted to the Ten. Excel rims are fitted and she is driving again now. Just have to wait about a week for the new �hlins shock for the rear. Oh, and some nicer weather for new photos would also be welcome... :eusa_whistle:

looks good buddy

Right! So today the weather was nice enough to shoot a few pics. Here she is with the revised front fork, front fender painted, Excel 18" rear rim. By the way, those are my offroad wheels, momentary with Karoo 3 mounted for an upcoming trip in Finland. I have a set with black Excel rims (also 18" rear) for street use as well. Will make a photo of that mounted later as well. Just have to wait for the rear shock to arrive.

http://i58.tinypic.com/21aef6u.jpg

Up front is a 320 mm wave disc mounted, rear also a nice looking wave. Master brake-cylinder comes from a KTM 660SMC. The right setup for a single disc Tenere, giving a very clear pressure-point and a steady build up of brake force, without getting agressive. However, emergency-braking asks for a more powerful pull on the lever.

http://i62.tinypic.com/8w0apd.jpg

Renthal Fatbar mounted on ROX-risers:

http://i57.tinypic.com/sz7gqw.jpg

Awesome.....
 

Hi Harry

Looks fat your new front.......and the hole bike - WOW - nice job done buddy.

Have a lot of fun with your "new" tenere and please write how the difference between the forks are......we have many KTM-stuff and -people also here in Switzerland.......:).

enjoy your rides and happy Harry-Frontwheel-regards:)

Andy

And a closer look at the seat. In one word: Fabulous! This guy really understands another bikers wishes!

http://i58.tinypic.com/qx066h.jpg

http://i62.tinypic.com/kestw1.jpg

Two more: loving this bike... :wav:

For the next photos i hope to have the rear shock mounted as well. With this front fork mounted, the difference in quality with the standard shock becomes almost dramatic.
You might also note that it is missing the side stand? I made that one a bit longer to match the new hight, and it is now out to get a fresh powder-coat. Also have to do that with the main stand, as it stands with both wheels firmly on the ground now.

http://i61.tinypic.com/2cd9xyq.jpg

Seen those new green rings on the front fork? They do not exactly match the color, but they have a practical use. Mud-scrapers they are, a first barrier that removes mud and dirt from the inner legs before it can get to the dust-seal section and the oil-seals inside.

http://i57.tinypic.com/iqy6mc.jpg

Hi Andy,

Thanks! This front fork is really great, specially after having it readjusted! The bike feels so much steadier already, you would not believe! How this takes bumps, wow... Cannot wait to have the rear shock done as well...

Hope you enjoy your new front wheel as well!

PS. a tip about the forks, coming straight from the specialist, a former chief mechanic at WP, until KTM took over. WP used to be a Dutch company you know... If you can get your hands on one, go for the older type 4860, as the chrome on the inner legs seems to be much stronger than the new ones. He could not tell if that had to do with environmental issues in chroming, or just a cheaper manufaturing method, but the quality-difference seems to be huge... Mine is a 2008 one, which is still the "good" type.

Hi Harry

Wich hand guards are these?
And the front fender, where it comes from?

Good job mate!

Looks sweet Harry. Well done. :023:

I must say, silver rims make the Z look about 50Kg lighter! ;)

KTM 640 Adventure mudguard??

Hi Jaume, those are the "old style" Acerbis rally handguards, the type is Rally Brush, and the spoilers are going separately. And then i got another mounting kit for the 28 mm handlebar.

Happy you like it! I really like yours as well by the way.

Actually, i got to find the guy who makes the rally fenders for our own Frans Verhoeven. He makes them both in polyester and in carbon/kevlar and the price is very good. Carbon/kevlar only around � 135,-, depending on how it comes out of the mold. But you get a lot of grinding to do, as it is still rough. Can give you his contact details if you like, in a PM.

Indeed, silver rims aren't so bad eh! The color was actually depending on the front wheel i got. The offroad front wheel (which is slightly dented by the way) happened to have a silver rim so my rear wheel also got silver.
For my street set i got my hands on a brand new front set, with a black rim, so also got the matching rim on the rear.

Nice to see the positive replies so far...

Thanks

The only thing I don't like it is the two levels seat. I had it but annoy me a lot.
Yes, silver rims look good!

I agree with that Jaume. But i asked the seat to be comfortable two-up, and to keep the double level as little as possible. Driver part got higher, while the passenger part got as low as possible, but also getting enough comfort for long distances. The way the subframe is constructed, to gain highth optically only, dictates how the seat was built up and with my specific wishes this really was the best possible solution. Make it a pure rally-seat and you get something as Jenny's Heroes Legend Tenere with almost no polstering in the rear part.Also the Touratech high is basically like that i think, taking rear polstering to its minimum.

The driver place is very spacy now though, completely the opposite of what it was originally. i am not achored in it anymore and can move forward and backward freely during driving. It really is a great compromise between rally- and touring-purpose. You could try for yourself if i would ever come across Barcelona... I should, though, as Morocco is still on my list.

Test-driving was done in Finland, a 2500 km offroad-tour last summer. (and a 2800 km route on- and offroad to get to Suomussalmi, the starting-point)
The Ten really handled great all the way, through every kind of terrain. I am in love for sure!
Only one weakness appeared. The mounting of the rear fender was too tight. It started to tear around the mounting points and eventually got caught in the rear wheel at high speed on gravel.

http://i58.tinypic.com/2hdw8dy.jpg

Temporary solution to hold the thing together for the days to come:

http://i60.tinypic.com/5v3a0.jpg

Never found back my licence-plate anymore so my original plan to return after this ride through the Baltic countries, Poland and Germany did not seem very wise to me. Driving through the Northern part of Finland was not such a big risk though, never saw any police. For the way back home fabriced this solution, thanks to Tupperware...

http://i62.tinypic.com/28hojcw.jpg

Anyway, the new rear fender (same as the old one) now hangs in 6 mm thick rubber dampers on both sides of the plastic. More flexible and should resist the vibrations now. Also gives a better visibility on the tail light now. We learn as we go...

The Arctic Circle did not look very Arctic early august... Around 30 degrees Celcius.

http://i60.tinypic.com/2e5pl35.jpg

We had around 24 degrees at the Nordcape in 2011.

After having my DRC Anato tail-tidy broken off for the second time during offroad riding, i now decided this thing is not offroadworthy at all.

http://i65.tinypic.com/rhtv7r.jpg

Off goes the DRC, on comes an aluminum part from S-moto, hope that will be stronger!

http://i63.tinypic.com/noitf8.jpg

http://i64.tinypic.com/143olk9.jpg

http://i66.tinypic.com/6zlq1d.jpg