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Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

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Photo by Alessio Corradini,
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  #1  
Old 22 Oct 2008
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Interested in 2002 640 Adv
I'm looking at a '02 Adventure and I was just wondering what the deal with the stater motor problem is.
It's got 25000 miles on it,hard panniers.
Asking for 3850 Euro.
Any opinions?
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  #2  
Old 22 Oct 2008
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Hi there - I've had an '02 adv for 18,000 miles and counting and haven't had a problem with the starter motor itself ... just the occasional flat battery from lack of use.Mine kicked overpretty easily as well, as long as there was some charge left.... oddly ,the kicker won't work if the battery is completely flat (thereby defeating it's purpose, to my mind).Anyway ,have a look at the 'thumpers' thread on advrider for a more detailed discussion.Apologies if I've taken you're thread off on a tangent!
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  #3  
Old 23 Oct 2008
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I have an 02 Adventure, it had 11,000 km on it when I bought it 2 years ago, and have put 29,000 km since. I have never had a problem with the starter. I did have to replace the clutch main shaft bearing (the bearing behind the clutch). If the bike you are looking at has the old style ball bearing, it should be replaced with the new (03 and up) roller bearing. This is fairly easy to do yourself if you are moderately skilled mechanically, go to the KTM talk site for instructions. It does need to be done, don't wait for it to fail (like I did).
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  #4  
Old 25 Oct 2008
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Deal done
I am now the proud owner of a '02 640 Adv.
Swopped it for my '03 CCM R30 motard.
I feel it's a natural progression from my '90 XT600 Tenere.
I just hope that they get on together in my garage.
Now,I need to go someplace.
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  #5  
Old 30 Oct 2008
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Quote:
Originally Posted by Burgo View Post
oddly ,the kicker won't work if the battery is completely flat (thereby defeating it's purpose, to my mind).Anyway ,have a look at the 'thumpers' thread on advrider for a more detailed discussion.Apologies if I've taken you're thread off on a tangent!
More off-topic... but check the same thumpers section on advrider for the solution to the kicker not starting without battery. You have to unplug the headlights if I remember correctly.

Congrats on the new bike cathal! It's a darn great machine!
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  #6  
Old 1 Nov 2008
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[quote=2cvfred;213017]More off-topic... but check the same thumpers section on advrider for the solution to the kicker not starting without battery. You have to unplug the headlights if I remember correctly

had a look but could not find any more on starting on a flat battery, would realy like to know if it can be done?
cheers
iain
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  #7  
Old 1 Nov 2008
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Have a good look at the index page at: KTM LC4 (640) Thread Index - ADVrider

It is packed with information on LC4's!

The one of interest to you is: Kick-starting LC4 with dead battery? - ADVrider

I haven't tried it myself though... the e-start is easier ;-) But sure is good to know when you are out in the sticks...

Cheers,

Fred
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  #8  
Old 2 Nov 2008
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Lights
Thanks for the advice. That Advriders website is good.
I put a couple of hundred miles up today and I have to say I'm impressed with its handling on fast twisties.
I have to say that the lights on my Tenere are far superior. That main beam is a joke.
I've been kicking it with no problems as the starter clutch sounds like it needs some TLC.
I also raised the needle one notch and disabled that solenoid that limits acceleration in 2nd and 3rd gear. It now pulls between 3 and 4k revs. I want to gear it to do 100kph at 4k rpm like my XT.
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  #9  
Old 2 Nov 2008
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I have an '07 640 that had a failed started due to the wiring failing...
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  #10  
Old 2 Nov 2008
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Cathal,

I have a LC4 dual-curve ignition box for sale: http://www.horizonsunlimited.com/hub...box-sale-37356

Blatant plug, I know...

Cheers.
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  #11  
Old 12 Nov 2008
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Quote:
Originally Posted by cathal View Post
I'm looking at a '02 Adventure and I was just wondering what the deal with the stater motor problem is.
It's got 25000 miles on it,hard panniers.
Asking for 3850 Euro.
Any opinions?
One well known problem an LC4 can experience at around 20k miles involves the breakup of the gear between the starter motor and crankshaft - is this perhaps the one you refer to?

It's not a hard fix, it simply means replacing that one gear and removing any metal swarf that will have been created.

One theory says that because it's a reasonably high compression engine, if you try to start it but fail, the kick-back from the piston is absorbed through the teeth of this gear, and that's what can cause the damage.

Paul G
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  #12  
Old 14 Nov 2008
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[quote=cathal;213500]...
I have to say that the lights on my Tenere are far superior. That main beam is a joke.

Then there is something seriously wrong with the lights on your KTM. I have never seen a brighter light. Maybe the adjustment? Also check the suspension, especially the rear. The PO of my my bike had wound the rear spring preload all the way down, probably to lower the seat height, but there wasn't much he could do to lower the front. The low ass end resulted in a head light that was more of a search light. Putting the suspension back to normal fixed it.

(If you need to adjust the rear spring, the easiest way to do it is to remove the entire shock and spring unit, it doesn't take long and gives you the opportunity to inspect the linkages making sure they are all greased etc..)
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  #13  
Old 14 Nov 2008
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Adjusted
I wound on the preload on the rear and adjusted the angle of the lights. Better but still not great. It's the spotlight effect of the main beam that gets me. Loads of light straight ahead but nothing at each side. And the reason the lights seem better on my Tenere is due to the fact that I'm not approaching the darkness as quickly. It would be nice to have the dim on at the same time to light up the peripheral areas. Oh, and the dim is angled the wrong way,right into the eyes of oncoming traffic. If I lower it to fix this,I can only see about 5 feet ahead.
Seems to be a RHS of the road lens.
No difference to me now,I'm in the USA for the forseable future,thinking of all my lovelys back at home.
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  #14  
Old 24 Nov 2008
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Quote:
Originally Posted by cathal View Post
I wound on the preload on the rear and adjusted the angle of the lights. Better but still not great. It's the spotlight effect of the main beam that gets me. Loads of light straight ahead but nothing at each side. .......
Yup, so keep your speed up so's you don't have to worry about stuff coming at you from the side :-)
The Harley Dealer may be able to fit some electra glide spotlights, that is if you can find one that won't chase you out of the parking lot "we ain't got no metric tools geddoudahere!"
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  #15  
Old 30 Nov 2008
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'02 KTM Adventure
My '02 Adventure has over 30k miles and is running strong.
Just my 2 cents. Grease everything, wheel bearings-pop the grease seals and dab some in, check the cush hub bearing for rough rnning, grease steering head bearings, swing arm bearings/bolt, shock linkage-grease all the bearings in the pivot, bleed brakes to get new fluid in circulation.

Pull off valve gear cover and check cam followers for wear at the roller bearings, rebuild the water pump/replace seals at least and rotor. Reseal the valve gear case with Hondabond.
Torque the headbolts and ESPECIALLY tighten the front and rear head bolt nuts. I would remove them, add some locktite and reinstall them.

Replace the clutch/trans bearing as suggested. When you have the clutch case off it is manditory to replace the lip seal on the end of the crank that is mounted in the clutch case. If it fails your engine will die.
bill
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