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Photo by Lois Pryce, schoolkids in Algeria

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  #1  
Old 10 Jun 2007
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2000 KTM 640 LC4 Adventure R - GREAT bike!
Hello...

I ride a 2000 KTM 640 LC4 Adventure R.

It has been a GREAT bike, and required periodic maintenance of course...
but I have only had two 'failures', and they are both known.

1) ~ 4,000 miles: Clutch cable break.
2) ~ 8,500 miles: Front wheel bearings replaced.

I have just ordered the SW-Motech sidestand so that I can retain the centre stand but still mount and dismount such a tall bike with the Touratech ZEGA panniers mounted.

This bike ROCKS. It's absolutely capable of anything, has great power and versatility, rock-solid reliability, and is (relatively) devoid of all the superfluous crap that would make a lesser bike less good.

i suppose I'm preaching to the choir in this thread, but I thought I'd sing the LC4's praises anyway. I am looking forward to a long lifetime of exciting adventure touring on this faithful steed!

Cheers,
-southpaw, Seattle.
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  #2  
Old 28 Sep 2010
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KTM LC4ADV 2003, 30000km
6000 km - new cylinder (micro crack... leaking water) no warranty, was in 2009
30000 km -nothing but normal wear parts
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  #3  
Old 7 Nov 2010
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Just started a major rebuild on my 640 at 95 000 km, details over on advrider:

Clintnz's KTM 640 95,000km service - ADVrider

There are a couple of other guys doing some maintenance on their well travelled LC4's also & posting up the details on advrider, plenty of good info for anyone with lots of miles on their 640.

Cheers
Clint
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  #4  
Old 3 Oct 2012
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Bumping this thread so that peeps can update or add their history!
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  #5  
Old 6 Oct 2012
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I have had all the well known issues with my 2006 adventure.

Cam follower bearing at 40k
Broken tooth of starter gear destroyed stator.
Broken rear sub frame
Steering head bearings

Leaking base gasket at 50 k so did a top end rebuild at the same time.
Leaking fork seals

Clutch replaced at 55k

Usual consumables chains sprockets brake pads wheel bearings tyres etc

Frayed wires under the dash caused all sorts of issues.

Currently have the carb off chasing a bogging issue.

Bike has now done 65 thousand hard klms and I still love it, although the relationship gets a bit strained at times.

If they were still making them I would buy a new one. Would love a 690 adventure but obviously never going to happen, so I am going to hold on to the 640
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  #6  
Old 7 Jun 2005
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2005 ktm 640 Had to replace battery after 1200km would not hold charge. Front left fork seal leaking at 5600km and have done only 600km on good dirt also oil window seeping
Regards Dave.
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  #7  
Old 8 Jun 2005
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2001 23000 km

Here's my list;

2 front spokes

ehhh,
That's all.

A little (motocross)tip;

A leaking forkseal is not always a broken seal.
Most of the time it's just some dust.
Take a foto-negative(?), cut it so, that you have a sharp end.
oil it, and press it between de seal and the forkleg. Go around the forkleg.
Big change the leaking is over.

[This message has been edited by Freek (edited 07 June 2005).]
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  #8  
Old 15 Jun 2005
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The dealer just fixed a leaky valvecover (u know, only sealant) on my 03 at about 24000km's. There were some minor issue's (bolts etc) but nothing worth mentioning, its
very reliable.... (and a beauty to drive offroad)....

A good tip is to insulate your electrical wiring in the cockpit, its a job not well done by KTM. Most wires are rubbing against the frame which has caused a short on me before. While doing that i found some other wires with the insulation rubbed through....

[This message has been edited by gozell (edited 15 June 2005).]
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  #9  
Old 23 Jun 2005
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the good has turned bad, 200km after the last post the bike was not running good at all. after taking my earplugs out and letting it idle, it was quite clear... big-end bearing needs replacing... at the moment its a the shop, engine being taken out and split...

the bike is out of warranty..


any ideas why this happend at only 24200km??? oil and filter changes were done at 3500km on average with quality shell vsx oil...
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  #10  
Old 24 Jun 2005
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Argghhh!!!

The reason I spent ages looking for a 2003 model was to remove the worries about exactly this problem!!!! I'd also love to find out why this might have happened. Are there any clues from the garage after they split the engine??

Dave
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  #11  
Old 26 Jun 2005
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Jerome,
What are the symptoms of a seized cam follower, is it a show stopper or just a noise generator. I guess it could damage the cam if left too long.

I am up to 40 K and will have a look at the next service.

Steve


the inlet bearing is quite a bit smaller than the exhaust one.
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  #12  
Old 27 Jun 2005
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Steve,

Yes, the inlet is weaker because it's smaller.

Symptoms - the valve gaps get very wide very quickly (>40 thou after 500km) once the bearing has seized and/or disintegrated.

The bike runs but only to the nearest shop.

I did 1,500km on mine at speed and buggered the valves as well.

Result
- new cam (lobe really worn down)
- new inlet rocker arm
- 2 new inlet valves and regrinding
- new exhaust cam for safety.

If i go up Africa im going to replace the inlet again (at 70,000km) to hopefully avoid problems further north.


------------------
Jerome

http://www.fowb.co.uk
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  #13  
Old 25 Jul 2005
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Quote:
Originally posted by gozell:
the good has turned bad, 200km after the last post the bike was not running good at all. after taking my earplugs out and letting it idle, it was quite clear... big-end bearing needs replacing... at the moment its a the shop, engine being taken out and split...

the bike is out of warranty..


any ideas why this happend at only 24200km??? oil and filter changes were done at 3500km on average with quality shell vsx oil...

FYI: make sure to put a small air filter on the brass carb tube when removing EPC... I didnt pay much attention to it and this is prob why sand ended up in the engine and started wearing things out.... As a result th e piston ring broke and caused some dammage, while engine was split big-end and a few other bearing were replaced in the process....

[This message has been edited by gozell (edited 24 July 2005).]
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  #14  
Old 1 Aug 2005
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Quote:
Originally posted by SteveAttwood:
Jerome,
What are the symptoms of a seized cam follower, is it a show stopper or just a noise generator. I guess it could damage the cam if left too long.

I am up to 40 K and will have a look at the next service.

Steve

Steve

I checked my inlet bearing at 39,000 km. It was in good condition. At 44,000 km it failed and took out the camshaft. Dont bother checking it, just replace it. I had no problems riding over 1000km with the failure. But the failure of a $20 part has cost me $500 (including shipping to Central America).

Oh, bike is a 2003 640 Adv. Same as Jeromes.

Dave
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  #15  
Old 2 Aug 2005
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Dave & Jerome
Thanks for the warnings. I had to fix an oil leak in the cam cover at the last service so I had a good chance to inspect them closely, the the inlet bearing looked OK but had some very slight pitting on the surface. Cam and everything else look good. Now I am up to 50k KM and I have a set of replacement bearings and pins and plan to do the job next week.

Steve
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