KTM LC4 Adventure-R Bike Preparation Checklist
 

KTM LC4 Adventure R Bike Preparation Checklist

Hope this helps: These are the modifications I have made to my LC4 Adventure-R (2001) before an overland journey from UK to India. Please comment/amend as you wish. (In no particular order).

Bike

„h Install Electrical Socket
„h Add additional crossbar to handlebar
„h Add Framebook frame holder (KTM part)
„h Fit Sidestand kit (remove centre-stand)
„h Weld 5cm plate onto sidestand
„h Reupholster seat & fit horses 'Equigel' Gel pad
„h Fit Touratech Frame
„h Fit Touratech Aluminium Zega Panniers
„h Suspension set under full load
„h Copperslip Spoke Nipples (Front & Back)
„h Copperslip back of brake pads (to stop that bloody brake squeal!!!)
„h Fit Bridgestone Ultra Heavy duty inner tubes
„h Fit Tyre/Rim clamps (to prevent type slippage)
„h Slime (puncture sealent) above inner tubes
„h Fit extra Air filter cover
„h Fit Air filter Sand Stop ¡V fine metal mesh (Remove air filter snorkel, cut to size, silicone stick)
„h Fit In-line fuel filter (from pump to carb)
„h Fit Small number plate with rubber mounts.
„h Fit Locking Petrol Cap
„h Practice removal of both Front & Rear wheel, air filter clean.
„h Stood with mechanic whilst performing service (invaluble!!!!)
„h Apply Loctite/Engineers adhesive to important bolts (aply small blob to outside)

Spare Parts:

„h 2 * Oil Filter Kit (inc 2*filters, seals & copper washers)
„h 1 * Brake leaver
„h 1 * Clutch leaver
„h 1 * Clutch cable
„h 1 * Throttle cable (2 cables)
„h 6 * Rear spokes (3*2 sizes)
„h 3 * Front spokes
„h 1 * Air Filter Oil
„h 1 * Engine Oil bottle (with tube)
„h 1 * Sand Stop spare
„h 1 * standard inner tubes (Front & Back)
„h 4 * Inner tube valve cores
„h 1 * Bulb set
„h 1 * Fuse set
„h 1 * Copperslip
„h 1 * Grease
„h 1 * Araldite
„h 1 * Superglue
„h 1 * Gasket in a tube
„h 1 * ¡¥Petro Patch ¡V fuel tank patch
„h 1 * Gaffer tape
„h 1 * Octane Booster fuel additive
„h Lots of Cable ties




[This message has been edited by JNTaylor (edited 12 October 2002).]

Bike

 Fit Sidestand kit (remove centre-stand)

My advise is that centre-stand is most useful for chain-wheels maintenance... consider leaving it in it's place.

A little care: in my old 2000 model, the side stand made impossible using the kick starter, check if it's true on the 2001 model too (and please let me know http://www.horizonsunlimited.com/ubb/wink.gif ).

 Weld 5cm plate onto sidestand

I don't know if it fits :-/. I allways use crushed a beer can, and parking turns to a pleasant occupation! http://www.horizonsunlimited.com/ubb/wink.gif))

 Reupholster seat & fit horses 'Equigel' Gel pad

Please, make a little report on this item, I'm most intrested... or better... an anatomical part of me is most intrested! http://www.horizonsunlimited.com/ubb/wink.gif))

 Fit In-line fuel filter (from pump to carb)

Check _carefully_ the pump functionality: mine is gone without notice, and is an awfull experience being stranded with no gas when you know there are aprox 8 liters of fuel in your tank (it appened to me http://www.horizonsunlimited.com/ubb/frown.gif(( )

 Fit Small number plate with rubber mounts.

Be _extremely_ carefull! Some policemans don't love this activity so much...

 Fit Locking Petrol Cap

This is not very usefull, a thief can "suck" your gas simply from the fuel cap.

Spare Parts:

 2 * Oil Filter Kit (inc 2*filters, seals & copper washers)

Don't forget the O-Rings!

 1 * Clutch cable

Consider Hydraulic clutch kit... My 2001 model buyed 01-06-2001, has 12800 Km... I've replaced 5 clutch cables until now...

 1 * Engine Oil bottle (with tube)

Make it 2...

 Lots of Cable ties

Invaluables! http://www.horizonsunlimited.com/ubb/wink.gif)

Have a nice trip! I envy you SOOOOOO MUCH! http://www.horizonsunlimited.com/ubb/smile.gif))

By!

Pietro (aka Badwolf)

------------------
Pietro Tosetti (KTM EGS 640 Adventure R 2001 "PRIS") &
Patrizia Coari (Honda Dominator 650 "Brontolo")
Milano - GFC 23 & 24 - EChM 499 <A HREF="http://www.pitpat.it
A" TARGET=_blank>http://www.pitpat.it
A</A> volte un atteggiamento rigido e' conseguenza di una paralisi.

Thanks Pietro, excellent advice... comments below:

Bike
 Fit Sidestand kit (remove centre-stand)

My advise is that centre-stand is most useful for chain-wheels maintenance... consider leaving it in it's place.

>>JT: I totally agree, but you can't have both on at the same time. I had to make a decision and felt it much easier to get off the bike (under full weight + panniers) with a side stand. I will use the aluminium panniers as a rest if possible. Or enlist the help of my friendly travelling companion!

A little care: in my old 2000 model, the side stand made impossible using the kick starter, check if it's true on the 2001 model too (and please let me know ).

>>JT: True - you must have the sidestand UP to kickstart - or it will break the sidestand spring or more...

 Weld 5cm plate onto sidestand

I don't know if it fits :-/. I allways use crushed a beer can, and parking turns to a pleasant occupation! ))

>>JT: It seems to fit quite nicely, but I'll still have a beer and drink it anyway. :-)

 Reupholster seat & fit horses 'Equigel' Gel pad

Please, make a little report on this item, I'm most intrested... or better... an anatomical part of me is most intrested! ))

>>JT: Easy to do (see separate mail in KTM Tech) - My standard seat had additional padding added to the existing foam. This adds about 2-3cm to the height & width. Then the gel pad (about 50cm * 35cm and 1cm thick - designed also to be a shock absorber) is placed on top of the new foam and held in place with new cover. This makes the seat about 5cm wider (this is good part) & taller (so you need long legs to ride bike as it's already on of the tallest bikes around!), but a joy. Before: 15mins ride before pain. After: 2+ hours!

 Fit In-line fuel filter (from pump to carb)

Check _carefully_ the pump functionality: mine is gone without notice, and is an awfull experience being stranded with no gas when you know there are aprox 8 liters of fuel in your tank (it appened to me (( )

>>JT: I will check with dealers about the warrently - I have read they they often break down.

 Fit Small number plate with rubber mounts.

Be _extremely_ carefull! Some policemans don't love this activity so much...

>>JT: They don't in UK either, hopefully a smile will help ;-)

 Fit Locking Petrol Cap

This is not very usefull, a thief can "suck" your gas simply from the fuel cap.

>>JT: Yes - I thought it was a good idea at first, but another key not-to-lose is a problem and now it makes a noise too. I might change back.

Spare Parts:

 2 * Oil Filter Kit (inc 2*filters, seals & copper washers)

Don't forget the O-Rings!

 1 * Clutch cable

Consider Hydraulic clutch kit... My 2001 model buyed 01-06-2001, has 12800 Km... I've replaced 5 clutch cables until now...

>>JT: Oh My God. I don't have time but will be able to visit KTM dealer in Istanbull & have spare - I will grease every day!

 1 * Engine Oil bottle (with tube)

Make it 2...

 Lots of Cable ties

Invaluables! )

Have a nice trip! I envy you SOOOOOO MUCH! ))

By!

Pietro (aka Badwolf)

don't forget to install the 3 'heavy duty' clutch springs.

Freek

Just to say that before taking O-rings check if you really need them. My ktm lc4 640 model 2001 does NOT have O-rings. The fabric mounts old good paper (whats the word?) now (like before 1999 as the dealer said). The O-rings seemed to leek more often. So if You have 2001 model you might not have O-rings.

------------------
Andrzej Kuczyñski
KTM LC4 640

About the clutch cable problem: change it for the Duke's cable. It fits and it's far stronger.

Locking Petrol Cap
 

hello JNTaylor
please what did u do to get a Locking Petrol Cap on ur 640 adventure
i have an 2002 adventure also i want to to install a cap with a key or another idea to secure the gas cap from anyone opening it?