Hi;
I have a problem about KTM Service in Turkey. Is there any contact e-mail in KTM Headquarters Austria?

Thanks

I've got 14k miles on my LC4, and have had 2 problems, first had a kill switch short out a certain RPMs when accelerating the bike, causing the bike to act like it was a fueling issue. I just unplugged the switch until I replaced it with a new one, easy fix. And now I've got a hole in the top of my motor.

Mine's an 03 640 Enduro, I've maintained her more or less by the book & she's been pretty good. Apart from the usual consumables of chains, sprockets, wheel bearings, brake pads, suspension servicing etc here's my list:

Countershaft seal @ about 12 000 km (they musta had a bad batch as the replacement is still going strong)

Re-sealed the seeping cam cover @ 20 000 km, Use good goo & there'll be no more problems.

At 45 000 km the intake valve clearance seemed to be opening up a touch so going off Jerome's recommendation I stripped the head at the 50 000 km mark & found that the intake cam follower roller was indeed showing signs of wear. Replaced that, all the other bearings in the head & the timing chain. The other bearings & the timing chain all seemed to be in good shape but the parts weren't too expensive so they got done.

5/2009 update: At 75 000 km now, (47 000 miles) & she's still going strong. From my experience I would rate the KTM 640 as a very well made reliable bike. And it goes fast!

6/2010 update: At 90 000 km now, (56 000 miles) she's still never let me down. Gave the carb a rebuild at 80K km as it was getting well worn. Also welded up a crack in the subframe & reinforced it. Keep a eye on the rear of the tool case mount tube, this seems to be a common failure point. Mine did a serious amount of loaded up, high speed, rough road hooning before it cracked though. Did another countershaft seal too to fix a slight seep.

I think I'll give the ol girl a rebuild at 100 000 km if she needs it or not. Cheap fun in my book.



Cheers
Clint

edit doesn't seem to be working...

I forgot to add the starter sprag clutch which I replaced at 50 000 km also. A simple job if you have the right puller, & not very mission critical anyway as the beast is fairly easy to kickstart once you have the knack.

Cheers
Clint

It's been almost 2 years since my last update so I guess it's time..... I've gone through 2 riding seasons with very little problems from the bike but late last fall another one crept in....

Nearing the 85,000 KM mark my bike developed quite a coolant leak into the combustion chamber so I pulled the top end and found a faulty head gasket.... While I had the head off I sent it in for a valve job to restore the seats.... I ended up having to replace all the valves and guides due to wear at this time..... I then installed the restored head and upon inspection after the test ride I detected a very minor coolant leak in the right exhaust port....
To make a long story short: I ended up with a very small {almost undetectable} leak between the head and the valve seat.... My cure for this was to pick up a used head and fork out another hefty sum for more valve work and a new head gasket.... I don't mind paying for one valve job every couple of years but paying for a second one kind of hurts....

I own a 2007 ktm 640 and road it from Cape Town to Cairo , not one problem
it is the only bike i would use on a trip like this.

cheers
Philip

Hi everyone

Do you know if CountPacMan who started this thread back on 14th July 2005 actually did finish the compilation of an issues lists covering the KTM 640?
Alternatively did anyone else?

... for those KTM 640 Adventure enthusiasts who dont know I recommend the following link: KTM LC4 (640) Thread Index - ADVrider

Cheers

Gade
New owner of 2002 640 Adventure

+1 and the footprint is useless off-road. A pencil would be more use.

__________________
http://bigben.to/ London to....? The big bike annual rally.
http://www.mongolbikers.com 125cc London -> Mongolia.

I read this topic before going on my trip, i never thought i would get to post in it too. I have a problem, BIG one that is, so i'm asking for your advice.
Being in Altai mountains, near Ak-Tash and going to Mongolia, i dropped my bik in a big pond, with some mud on it. Not gettng to stop the engine quick enough, in got a few gulps of dirty water in the carburettor and then in the engine. Changing the air filter and the sparkplug seemed to make it work fine at that time, so i went on with it. But after 500km or so, it started consuming lots of oil. So much that it freaked us and decided to head back to Barnaul, where we opened the engine and found the piston rings were worn out. Changed them, and the bike still has little power, low compression as one can feel in the kick pedal and also most alarming of all consumes lots of oil, about 1 liter/300km.
At this point i don't know what to do next, if it is valve rings wear, then mybe we cantry gettingand fixing them in Amaty, as we are now 900km from it, but if it is cylinder wear we have no choice but to drive it as it is and complete the oil every 100kms. When weopened it, we could not see any visible signs of wear, and yet, the oil is going away like crazy.
Thanks for your help,
Alex

It's time to update again: The last one was at 85,000 KM... I am now up to 122,000 KM....

My auto decomp cam is now worn out so I use the handlebar lever to assist on cold starts... I've replaced the needle jet/jet needle again due to wear..Replaced the chain sprockets a few more times{since 85,000}... Replaced the suspension dog bone link due to wear.. Replaced the exhaust follower roller and rebuilt the waterpump as well....

Over the winter I plan to do a bit of engine work:

Replace the camshaft, camchain and sprockets.... Replace the intake follower and piston rings... Replace the clutch, check and replace {if required} the oil pumps and the oil bypass piston spring.... Measure gear shaft and crankshaft slop and replace bearings if required.... Send the head in for valvework....

Hi there,

On post no 52 there´s a link to the ADVrider site for problems on the LC4.
Now, i got the problem that i need to replace the oilseal at the drive shaft.
I´ve never done that before and thaught it would be a good help if i can print that description on that site how to do it.
I opened it a couple of weeks ago and i could see everything. Now, i´ve tried to open it through different browsers but the pictures don´t open. So i only got the text. Can somebody tell me what´s wrong? Is it the site or does it depend on the internet connection, or something else?
Hope to hear from you.

Cheers, Bossit! :-)

The fellow that posted the pictures on that thread {and many others} pulled all his photos from them....

Most of the time it's not the actual oil seal that leaks at the countershaft.... Before you attempt to change that seal check the condition of the O-ring behind the countershaft bushing... A shagged O-ring is likely the cause of your leak... I believe the replacement is a 2x25 MM...

6000 km - new cylinder (micro crack... leaking water) no warranty, was in 2009
30000 km -nothing but normal wear parts

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

Bumping this thread so that peeps can update or add their history!