My KTM 625 SXC Adventure bike build

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I bought a low mileage 2004 KTM 625 SXC to replace my trusty and immaculate Transalp. While the Transalp has been a great bike, it's really a bit big and soft for some of the places I seem to enjoy going. One day there will be tears when it all goes pear shaped so I decided to get something a bit lighter and more suitable in the gnarly bits, yet still capable, if a little less comfortable, of some decent mixed road trips as well.



The EQ has meant I had a wee bit of time to have a good look at the KTM and install some of the items that are not getting sold with the Transalp. So the heated hand grips are on and going and I have figured out where the Pro-Oiler (www.pro-oiler.com) components will go. There’s not much surplus space on the SXC compared to the Transalp but there seems to be a space for everything.



Some bits and bobs are winging their way from the good ole US of A. Some other bits were ordered from Superior Motorcycles to support the locals where the cost of doing so was not prohibitive but I figure it will be a fair while before those will be available considering the destruction inside the 4 Avenues.

My brand new Shoei Hornet (KTM Orange of course ) was still in its box waiting to come home from work and it is unlikely that we will be allowed back into the building – bugga!



The first items to be attended to will be a KTM 18 litre tank, comfort seat, pillion pegs, screen and/or fairing and a luggage system.

Nice to have a new project on the go

[Taz]

Here's one I prepared earlier

[clint640]

Nice! Welcome to the orange side That looks like a tidy one. No doubt you have found the LC4 index on advrider?

Cheers
Clint

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No doubt you have found the LC4 index on advrider?

Cheers
Clint

Yep, found that a while ago. How's yer rebuild coming along?

[clint640]

Yep, found that a while ago. How's yer rebuild coming along?

Back on the road last week & she's purring like a happy kitten.

One thing you should sort out before the 1st gnarly ride is a proper chain guide. Having the chain fed off the sprocket every time you get in a deep rut is a PITA. That little plastic flap is pretty useless, you can get an early LC4/Husaberg part off the KTM dealer that will bolt on.

Cheers
Clint

[Night Falcon]

Nice one....look forward to seeing the progress.

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Back on the road last week & she's purring like a happy kitten.

One thing you should sort out before the 1st gnarly ride is a proper chain guide. Having the chain fed off the sprocket every time you get in a deep rut is a PITA. That little plastic flap is pretty useless, you can get an early LC4/Husaberg part off the KTM dealer that will bolt on.

Cheers
Clint

Thanks, will do. T.

[clint640]

Thanks, will do. T.

It amazes me the amount of LC4's I see with a bash plate, but no proper chain guide. If you're planning on being in a situation where you might need a bash plate, you are DEFINITELY going to need the chain guide. It's also a good way to pick out the ones that haven't been used for much gnarly offroad stuff.

Cheers
Clint

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[clint640]

I bet I know what's in that box You might find you need some extra fuel line to fit it, not sure about the FCR but the tap ended up quite close the carb inlet on mine so I had to use a loop of hose to avoid kinks.

A mate who does some fibreglass & CF stuff as a sideline is currently making me some carbon-kevlar tank guards for my 18L tank, to glue onto the leading edges.
He's got too much work on to make any more sets but said I can have the molds to get someone else to make some more if there is interest from others.

Cheers
Clint

[Waihou Thumper]

The choke button is also a bit of a pain in the arse reaching up alongside the tank with the FCR

[Waihou Thumper]

It's also a good way to pick out the ones that haven't been used for much gnarly offroad stuff.
Cheers
Clint

I disagree, the bikes can still 'gnarly' with a OEM chain guide....I had one on my LC4 Adventure and have one on the 625, it is still intact. It has had it's moments....
Tell ya what though, the KTM original chain guide is way better than Touratech at half the price too.. Didn't last 5 minutes before it snapped....

[rogerh]

I never had the problem with the chain guide. Have managed to bend a rear sprocket tho (Impact damage)
Maybe I run my chain too tight?? And it stays on the right side of the guide. I think I have only got it on the wrong side of the guide once, and during a pretty good off.

Put the comfort seat high on the to do list. I have only just put an 18l tank on mine, and I love the range, but I am still not used to the extra bulk up front, and find it a bit unnerving still. Got too used to the 11l std one I think.

With the choke on the FCR, I put the cable from the BST into the FCR, with a few minor mods to the valve to make it fit. Works a treat. Don't know if I would bother again though as the requirement for a choke on a pumper carb is a little academic here in the north. May be more in the south, but I don't generally ride down there in the winter.

I manage to break most of the accessories on mine, but the bike is seemingly bulletproof, so make the mods strong. Just my 0.02c

[yafeetup]

It amazes me the amount of LC4's I see with a bash plate, but no proper chain guide. If you're planning on being in a situation where you might need a bash plate, you are DEFINITELY going to need the chain guide. It's also a good way to pick out the ones that haven't been used for much gnarly offroad stuff.

Cheers
Clint

my 625 has been on lots of really gnarly true off road rides ,its done 15000 km and have never had an issue with the guide. The 18 ltr tanks biggest issue is the increased dive under brakes when full, this is a small price for the range and increased radiator protection

[timg]

I bet I know what's in that box You might find you need some extra fuel line to fit it, not sure about the FCR but the tap ended up quite close the carb inlet on mine so I had to use a loop of hose to avoid kinks.

Cheers
Clint

Yup

There is a preformed fuel line for the FCR as a std KTM part for the big tank which I have ordered - only $8. Now the cordon has been lifted around a portion of the outer CBD I the parts I ordered locally may become available


I managed to peel the decal off the shroud and reuse it on the tank. Not a perfect fit but not too bad IMHO.

Put the comfort seat high on the to do list.

With the choke on the FCR, I put the cable from the BST into the FCR, with a few minor mods to the valve to make it fit. Works a treat.

Comfort seat is ordered SWMBO ain't too impressed with the idea of what the SXC offers as std. I'd read about the choke conversion on KTM talk, good to know it works well. My SXC seems to need choke at the beginning of the day and then it's sweet. I had it drummed into me as a kid to always warm up an engine before using it. I start my bikes, then put in my ear plugs, helmet on & gloves on by which time the KTM runs without choke so the awkward location isn't too big a problem at the moment. Winter might be a different story. My Ducati won't even consider running until it's well warmed up.



Another parcel turned up from the States Just like Xmas around here at the moment.