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13 Oct 2014
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Need Help
Good Day
Myself and 2 friends are doing a 8000Km trip through Africa (South Africa – Namibia – Zambia – Malawi and Mozambique)
We got KTM 640 Adventure 09 and 2000 models and bought them from a guy in South Africa
Both of them got around 43 000 Km on them so what I would like to know as I’m not very familiar with KTM (Honda Man) what must we have looked at before the trip and most important what spares would you recommend taking along on our adventure.
Now the bikes did a trip from Germany to South Africa so it got all the long trip conversions done.
Any recommendations will be appreciated
Thanks Peter
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13 Oct 2014
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R.I.P.
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Join Date: Aug 2003
Location: california
Posts: 3,824
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I'd start off by reading this thread from the beginning ... it started in 2004!!
Then go over to ADV Rider (Thumpers section) look up the 640 ADV specific threads over there. Some VERY comprehensive ones by guys who have been dedicated to this bike for ages. A TON of knowledge.
Look up a Canadian guy on ADV Rider (Gunnerbuck) He knows the 640's very well. Don't read too much ... or you may never go on your trip. Not ALL news is good news regards this bike!
I love the 640's ... to ride, but not so much to own or to travel on. But if you deal with all the common issues, carry spares and know your ins and outs of the bike ... you should be fine! 
Safe Travels!
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26 Jun 2015
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Join Date: Nov 2006
Location: NorthVancouver Island
Posts: 137
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Time to update: At 127,000 KM I rebuilt my engine, including splitting the cases and replacing a worn countershaft, since then the bike has been worry free for a few yrs... I am now approaching 202,000 KM and it is just starting to use a bit of oil meaning the rings and valves could probably use a service in the next 20,000 km.. One thing I have found is that the top end component life increases considerably with a more free flowing exhaust installed instead of the OEM unit...
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19 Aug 2015
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Contributing Member
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Join Date: Jul 2005
Location: Wirral, England.
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Quote:
Originally Posted by mollydog
I'd start off by reading this thread from the beginning ... it started in 2004!!
Then go over to ADV Rider (Thumpers section) look up the 640 ADV specific threads over there. Some VERY comprehensive ones by guys who have been dedicated to this bike for ages. A TON of knowledge.
Look up a Canadian guy on ADV Rider (Gunnerbuck) He knows the 640's very well. Don't read too much ... or you may never go on your trip. Not ALL news is good news regards this bike!
I love the 640's ... to ride, but not so much to own or to travel on. But if you deal with all the common issues, carry spares and know your ins and outs of the bike ... you should be fine! 
Safe Travels!

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Sounds like more trouble than it's worth..
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
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21 Aug 2015
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Quote:
Originally Posted by *Touring Ted*
Sounds like more trouble than it's worth..
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To tell you the truth, the 640 has never broken down or left me stranded on any trip... In fact the 640s that accompany me have a fairly reliable track record compared to some other brands of singles along on these rides.... We have had more than a few DR 650 failures, most notable were blown engine seals and burnt clutches... Dr 400 stator problems.. The BMWs had shock failures, plastic pieces rattle or break off the bike, wheel adjuster issues, ABS issues, blown forks seals and soft rims.. KLR 650 -Electrical failures , suspension failures and oil use issues...
A motorcycle that lives a soft life is going to in all likely hood last longer than ones that see hard miles ... For my personal type of riding I don't see a motorcycle out there that would stand up any better than my 640 has to what I have asked of it... I have been waiting for yrs for a better ride {for my needs} to come out and it hasn't happened... So far the manufacturers only seem to be focused on the fat pig Adventure market as to where they are producing large displacement, heavy, high hp multis and labeling them as Adventure bikes... They do for sure fill that role for a certain segment, but for some people an Adventure bike signals something that is more capable when you leave the beaten path..
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21 Aug 2015
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In the process of buying a '05, will update once I get it
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