KTM 640 Rally Frame Rebuild – Steering Bearings, Swingarm & Chassis Assembly (Ep. 6)

🏍️ KTM 640 Rally Bike Build Series – Episode 6 In this episode, we shift focus from the engine to the frame and chassis rebuild of my KTM 640 Rally. After starting the engine rebuild in the last episode, I take you through everything I’ve been working on behind the scenes to prepare and assemble the freshly sandblasted and powder-coated frame. This episode covers the complete frame bearing overhaul, including steering head bearings, swingarm bearings, linkage bearings, and chassis assembly. If you’re restoring a KTM 640 LC4, building a rally bike, or doing a full motorcycle teardown, this episode is packed with practical tips to avoid common mistakes and future headaches. 🔧 What’s covered in this episode: -Frame prep after sandblasting & powdercoating -Steering head bearing removal & installation -Triple clamp bearing & seal replacement -Swingarm bearing and seal installation -Linkage arm bearings pressed into the frame -Cleaning powdercoat from mounting points -Proper greasing techniques for long bearing life -Installing triple clamps, forks, handlebars & controls -Fixing electrical grounding issues after powdercoating -Rear shock installation and chassis mock-up ⏭️ Next episode: We return to the engine to finish the rebuild before installing it into the frame. 👍 If you enjoy motorcycle rebuilds, KTM LC4 projects, rally bike builds, and detailed workshop content, consider liking the video and subscribing to the channel. Timestamps 00:00 – Intro & episode overview 00:10 – Frame sandblasting & powdercoating prep 00:40 – Removing bottom triple clamp bearing 01:17 – Heating steering head bearing for easy install 01:31 – Steering bearing races & pressing them in 02:15 – Preparing for swingarm bearing installation 02:55 – Pressing in new swingarm bearings & seals 03:20 – Greasing swingarm bearings 03:45 – Mock-up assembly before final torque 04:00 – Installing linkage arm bearings in frame 04:10 – Pressing linkage bearings & creating seal clearance 05:30 – Installing rocker arm 06:05 – Mounting handlebars & controls 08:05 – Installing grips using brake cleaner 08:55 – Ignition coil grounding after powdercoating 09:50 – Rear shock installation & Dakar tank plans 10:00 – Outro & next episode preview