Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => KTM LC4 400/610/640 & 690 => Topic started by: blauth on October 02, 2010, 10:41:51 pm

Title: KTM 640 - Dedicated thread
Post by: blauth on October 02, 2010, 10:41:51 pm
I have just bought a 2005 640, 4500km and I have a few questions:

1) What is everyone going on about with the vibes? Hasn't bothered me yet. The motor does however sounds like a bucket of bolts being shook around. Is this normal? I have a Honda Transalp too (TA700) that is incredibly quiet in comparison. This worries me because I have read about main bearing issues on this bike. With this kind of mileage, I am not expecting any engine issues.
2) It still has the stock pipe and the bike feels really flat in the lower revs? I stuggle to lift her in second even with the clutch. I must note that I am 2000m above see level (Jhb). It also seems to have a flat spot around 5000rpm
3) It's got a SW-Motec side stand. What a load of crap!!! You have to be careful it doesn't take your leg off because it springs back so fast. It's already sheared the mounting bolt off the side stand bracket. Scrap metal IMHO!!!
4) If I idle at the traffic light for a minute or two and pull off, she dies. Starts fine again right away but it's clearly a jetting issue. Pilot jet too small or big?
5) The headlights resemble Chrismas tree lights. They glow but are really ineffective. I think I will have to do an HID conversion on them.

I rode a mate of mine's a few days back with an acropovic pipe and it's a different bike. That is first on the list of goodies and a scotts dampner is next.

Some opinions from others who own this bike would be great.

I will post some pics tomorrow....
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: 2 Stroke Dan on October 03, 2010, 04:22:43 pm
640 is a great bike, motor could be stronger around the main bearings, but with care they last well. The vibration is a non-issue and these complaints are mostly baseless. I've done a lot of kms on 640's and vibes are acceptable. Still the best option for a complete adventure bike.
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: 2 Stroke Dan on October 03, 2010, 04:26:31 pm
Sorry, I forgot, congratulations on your purchase, enjoy it!!
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: goingnowherequickly on October 04, 2010, 09:47:02 am
Got the same bike & love it to bits...
Unfortunately in the shop right now - big end failure .... KTM SA has helped me with a goodwill claim - think I was just unlucky to have it go at 30 000kms..
Agree with you about the stand, knocked my foot out when it was still new, and fallen over when idling, spring gets a bit softer in time tho...
perhaps consider a Leo Vince pipe , great pipe & makes a huge difference ,a lot easier on the wallet too...
 Like to see how to do the HID conversion..
Enjoy
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: domstes on October 04, 2010, 10:03:18 am
Hi

I know this is a link to another board, but the info on this page should answer most of your questions. It is also nicely indexed.

http://www.advrider.com/forums/showthread.php?t=86958
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: Rat Man on October 04, 2010, 10:12:37 am
Any suggestions for good affordable services for our beloved LC4's in KZN?
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: Panjo on October 04, 2010, 12:12:45 pm
Nice one. Sorry, 640 LC4 Enduro rider here. So because I don't have the BEEEG tank and the Funny headlights means I'm excluded from participating in this thread  ???

Title: Re: KTM 640 Adventure - Dedicated thread
Post by: AntonW on October 04, 2010, 01:43:51 pm
My 640 has done 60000km ( I got it with 27000Km) and now for the second time, first at +/- 33000km and now a gain the inlet rocker roller seized destroying the top of the motor. The first occasion the top was a right off and thanks to Rufus I manged to get a complete new top. This one has done the same thing. I have only had the bike serviced by KTM. I asked on both occassions as to the cause and I am still waiting for an answer.

The other problem has been electrical, which I put down more to wear and tear.

I have done the HID conversion. I had Krogs do the work, so they supplied the units (2) and added a rectifier so when switching to high beam the the low beam stays on. This cost me +/- R1500.00.

Check the rear suspension linkage for wear and insure it is well maintained. MP did a service and battled like hell to get it apart, all due to poor maintenance.

I love the bike even with the problems I have had.
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: blauth on October 04, 2010, 04:36:20 pm
Nice one. Sorry, 640 LC4 Enduro rider here. So because I don't have the BEEEG tank and the Funny headlights means I'm excluded from participating in this thread  ???



Better?  [changed title]   ;)
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: blauth on October 04, 2010, 04:40:50 pm
My 640 has done 60000km ( I got it with 27000Km) and now for the second time, first at +/- 33000km and now a gain the inlet rocker roller seized destroying the top of the motor. The first occasion the top was a right off and thanks to Rufus I manged to get a complete new top. This one has done the same thing. I have only had the bike serviced by KTM. I asked on both occassions as to the cause and I am still waiting for an answer.

The other problem has been electrical, which I put down more to wear and tear.

I have done the HID conversion. I had Krogs do the work, so they supplied the units (2) and added a rectifier so when switching to high beam the the low beam stays on. This cost me +/- R1500.00.

Check the rear suspension linkage for wear and insure it is well maintained. MP did a service and battled like hell to get it apart, all due to poor maintenance.

I love the bike even with the problems I have had.

So would you suggest a preventative replacement of that rocker bearing at 30k km? I am sure the replacement cost of a rocker bearing is significantly cheaper than a head.

My bike only has 4700km on it now and the thing really sounds rattly. All my mates who have had them assure me it's normal so I hope they are right. I have done about 200km on it and it's already pulling better. I think it just needs a little bit of KTM love........wide open throttle!!! >:D
Title: Re: KTM 640 Adventure - Dedicated thread
Post by: Panjo on October 05, 2010, 09:41:00 am
640 is a great bike, motor could be stronger around the main bearings, but with care they last well. The vibration is a non-issue and these complaints are mostly baseless. I've done a lot of kms on 640's and vibes are acceptable. Still the best option for a complete adventure bike.

Exactomundo! Oil change, Oil change Oil change. My bike vibrates but I'm used to it now. When I get on another bike, like a twin, it kinda feels strange not feeling the bike "Purr" below me. Torque is there in bucket loads. Power is available all the way through the gears. Suspension fantastic and the ground clearance make other DS bikes look like Crocodiles.

PS Thanks for changing the thread title  :3some:
Title: Re: KTM 640 - Dedicated thread
Post by: Panjo on October 19, 2010, 01:15:52 pm
Can anybody help? In the manual for the LC 4, it's states that when the fuel in the tank reaches a certain level, the trip meter will change to the F(Fuel) mode screen and you can monitor how many Km's you are doing. I was under the impression that an idiot light should light up as well.

I actually ran out of fuel, and ended up stranded on the side of the road because I was assuming that only once the idiot light came on, would I need to worry about fuel? Suffice to say, No Idiot lite ever came on or display changing to the Fuel Mode screen and I ran out of fuel. I was begining to think that i was riding a Diesel at one stage  :biggrin:

So, I've been looking at the tank, and I have had it off once or twice since since then, and I cannot see how my fuel tank, can notify the dashboard (Electronically or Manualy) regarding the fuel situation. Is it because I have the enduro model and this functionality is only available on the Adventure ?

Your help and advise is appreciated as always

Panjo


Title: Re: KTM 640 - Dedicated thread
Post by: Doerengone on October 19, 2010, 03:36:18 pm

Yo Panjo.
You probably ran out of fuel because you had the fuel petcock already on the reserve position. On mine, I ride on the normal ''on '' position untill the light goes on. Then you have a km or two in which to switch over to reserve position. On reserve you could do say 50km.
Title: Re: KTM 640 - Dedicated thread
Post by: Panjo on October 19, 2010, 03:44:50 pm
Thanks Doerengone but that's the thing... Before I changed the petcock to reserve I did not bet a warning lite. All that warns me is an engine surge and loss of power till I eventually change to reserve.
Title: Re: KTM 640 - Dedicated thread
Post by: Doerengone on October 19, 2010, 03:48:55 pm
Ok, my mistake.  Maybe the bulb has blown or the sensors moeg.
Title: Re: KTM 640 - Dedicated thread
Post by: Panjo on October 19, 2010, 04:06:30 pm
Aha. So that's the key. Where is this sensor located?
Title: Re: KTM 640 - Dedicated thread
Post by: Panjo on October 22, 2010, 02:02:43 pm
Can anybody help? In the manual for the LC 4, it's states that when the fuel in the tank reaches a certain level, the trip meter will change to the F(Fuel) mode screen and you can monitor how many Km's you are doing. I was under the impression that an idiot light should light up as well.

I actually ran out of fuel, and ended up stranded on the side of the road because I was assuming that only once the idiot light came on, would I need to worry about fuel? Suffice to say, No Idiot lite ever came on or display changing to the Fuel Mode screen and I ran out of fuel. I was begining to think that i was riding a Diesel at one stage  :biggrin:

So, I've been looking at the tank, and I have had it off once or twice since since then, and I cannot see how my fuel tank, can notify the dashboard (Electronically or Manualy) regarding the fuel situation. Is it because I have the enduro model and this functionality is only available on the Adventure ?

Your help and advise is appreciated as always

Panjo

BUMP....640 owners??? Any ideas

Title: Re: KTM 640 - Dedicated thread
Post by: AntonW on October 22, 2010, 02:33:59 pm
The petcock has 3 positions. When it is vertical it is off. With the arrow facing down it is on and arrow facing up it is on reverve. Always ride with it in the down position. When you feel the bike running out of fuel switch to the reserve (facing up) position. you should have about 2 liters left = +/- 30k's
Title: Re: KTM 640 - Dedicated thread
Post by: Panjo on October 22, 2010, 02:41:15 pm
Sure AntonW thanks, but do you not get a idiot light lighting up on your dash and does the  trip meter switch to the Fuel Mode? Like it says in the owners manual?
Title: Re: KTM 640 - Dedicated thread
Post by: AntonW on October 23, 2010, 11:03:15 pm
Yes it does, when I first got my 640 the light came on before I need to switch to reserve and now after. Don't know why but does not trouble me. I do love the 640.

As for the problem with the inlet roller it could be caused by long high speed riding so I am told.I have done lots of that at times
Title: Re: KTM 640 - Dedicated thread
Post by: Runner on October 24, 2010, 12:19:23 pm
My first bearing lasted 6000km, it started out as a tappet noise,  I checked the tappets, and the intake was to loose, so it got adjusted, and the noise was gone, but within 100km it was back, again the intake was to loose, and I then took the tappet cover off and saw the fucked bearing which I replaced and sold the bike on 27000km with that bearing still in.I have relaced a lot of them on customers bikes, but as to the cuase, I can only speculate, maybe low oil level or to little oil pressure.Also the bearing on the exh side is a lot wider so it will last, so maybe the intake bearing is under- desighned.
Sweet
Title: Re: KTM 640 - Dedicated thread
Post by: Runner on October 24, 2010, 12:37:35 pm
If you get it early enough you can get away with only the bearing,  but I have replaced rockers and a cam because of it, but never a complete head.
Title: Re: KTM 640 - Dedicated thread
Post by: AntonW on October 25, 2010, 01:03:58 pm
The time I replaced the head due to a large hole, the inlet had been replaced a short time before but not the rocker arm which.I suspect needed replacing and. Was not replaced. This time there was a large crack in the rocker arm. The cam was badly worn and had to be replaced.I have asked what the cause is and to date have not got a reponse from the KTM factory.
Title: Re: KTM 640 - Dedicated thread
Post by: blauth on October 25, 2010, 08:16:20 pm
After owning my bike for a short amount of time, I have a few distinct dislikes, not too many likes so hopefully most dislikes can be turned into likes with a few mods.

Firstly... The rims are sooooooft. VERY soft!!! Excel narrow rims is the answer....I think. Looking at about R1800.00 for the front wheel.
Secondly... The bike suffers from some serious headshake. Is this normal or do I need to put a damper on the bike. Any feedback here would be great.
Thirdly... I can live with the vibration...the rattly engine is very annoying.


Having said all that, here is some eye candy for this thread.....

(http://img259.imageshack.us/img259/6726/img2686a.jpg)

(http://img97.imageshack.us/img97/4338/img2694sm.jpg)

(http://img835.imageshack.us/img835/7048/img2753t.jpg)

(http://img99.imageshack.us/img99/9357/img2775p.jpg)

(http://img18.imageshack.us/img18/5504/img2788o.jpg)

(http://img181.imageshack.us/img181/3402/img2746.jpg)

(http://img708.imageshack.us/img708/5696/img2739g.jpg)

(http://img121.imageshack.us/img121/6749/img2695f.jpg)

(http://img843.imageshack.us/img843/6349/img2656a.jpg)



Title: Re: KTM 640 - Dedicated thread
Post by: goingnowherequickly on November 03, 2010, 05:07:01 pm
Any luck with the HID & dual light on high beam conversion...
Id appreciate some info on this.... preferably a kzn based shop..
fanks
Title: Re: KTM 640 - Dedicated thread
Post by: blauth on November 14, 2010, 08:43:28 pm
I went on a pretty neat ride today, pretty technical, riding over the mountain, some rocky paths, some superb winding jeep track, some rail road service roads and of course some dirt roads.

On the dirt road, it's not so cool. I want to know from those of you who own 640 adventures if they have steering head shake problems with their bikes. Mine just has to hit a tiny little stone and it shakes so violently that I almost crap in my pants. I stiffened up the compression damping which helped marginally but not much. Front wheel seems ok on the tar i.e. it feels balanced.


Is this normal? A mate of mine has a similar issue on his KTM990.


Is it something wrong with front suspension? The clickers are set teh same both sides. Perhaps the oil level or weight or something like that is differentin either fork.
Is it possible the back suspension? With sirt bikes, this is quite often caused from the back.

I need some help and advice here.
Title: Re: KTM 640 - Dedicated thread
Post by: Malibu on November 15, 2010, 07:50:07 am
Took mine for a ride along the Swazi border Saturday, so, round trip of 1200km's plus, did not get one head-shake.  Tar, dirt or tracks. 

I think she is set-up pretty much to standard setting on front and rear suspension, only had her 3 weeks now and have not really got into all the setting details yet, but shall do so some time when I get 2 seconds.

She seems to leap onto dirt and just perform... only thing I had was a few very small wash-outs on the front, but I think that's cos the tyres are pretty much in need of new rubber.   I ran her down the Belembu - Barberton road, which is fantastic, with serious switch-backs and a few really cool high-speed corners, pushed her apparently up to 140+ and there is no sign of any chicken strips on the wheels anymore, and did not have one moment of shudder or bar slap...

So, dunno what's happening with your bike. 
Title: Re: KTM 640 - Dedicated thread
Post by: Malibu on November 15, 2010, 08:19:29 am
Couple of pics from the weekend...
Title: Re: KTM 640 - Dedicated thread
Post by: Li on November 15, 2010, 08:54:07 am
I have had mine for 5 months now, got it at 8000 km's, now done just over 12000 km's.  All dirt technical and dirt highways.  When I first took her offroad I did suffer from headshake, got a fright on some of the loose rutted sections.  I set all suspension/compression to default as per manual  She has been great since, done about 3000km's on her since the changes, no more unstable/unruly behaviour.  Perhaps try starting as I did, from default manual settings, go from there?  Whoever you bought the bike from, obviously set the settings up for their weight and riding style, it suited them, now you set it to suit you? I do not have any steering damper on.
Just a thought, I am not the most technical person, this advise came from Blazes and Runner and it really did help?   :thumleft:
Title: Re: KTM 640 - Dedicated thread
Post by: blauth on November 15, 2010, 11:10:28 am
I have had mine for 5 months now, got it at 8000 km's, now done just over 12000 km's.  All dirt technical and dirt highways.  When I first took her offroad I did suffer from headshake, got a fright on some of the loose rutted sections.  I set all suspension/compression to default as per manual  She has been great since, done about 3000km's on her since the changes, no more unstable/unruly behaviour.  Perhaps try starting as I did, from default manual settings, go from there?  Whoever you bought the bike from, obviously set the settings up for their weight and riding style, it suited them, now you set it to suit you? I do not have any steering damper on.
Just a thought, I am not the most technical person, this advise came from Blazes and Runner and it really did help?   :thumleft:

Li, I think that's the most practical starting point that I will try. Another thing I am going to do is fit new tyres. I have the original Sahara tyres on it still. It will be a few weeks before I can give it a test because next weekend if 94.7 and I am off to the roof the following week. I will give some feedback after I have tested.
Title: Re: KTM 640 - Dedicated thread
Post by: AntonW on November 15, 2010, 03:09:39 pm
I have done +30000km and only time i have had a problem was after fitting a new front Tyre which disappears very quickly. Check your suspension settings, go back to standard and work from there. Remember to service the linkages on the rear shock. MP battled like hell to get it apart. My front rim laughs rather than smiles and still causes no wobbles or shakes
Title: Re: KTM 640 - Dedicated thread
Post by: blauth on November 15, 2010, 05:12:42 pm
I have done +30000km and only time i have had a problem was after fitting a new front Tyre which disappears very quickly. Check your suspension settings, go back to standard and work from there. Remember to service the linkages on the rear shock. MP battled like hell to get it apart. My front rim laughs rather than smiles and still causes no wobbles or shakes

I have a smiley or two but they are really not bad. Lets go back to standard settings and see how that works out. What tyre pressures are you running. I was running it at road pressures i.e. about 2 bar.

It feels vague in corners with that pressure but that's understandable. I am very relieved to hear that you guys don't have issues. It's not a general problem with the geometry of the bike then.

Thanks for the help.
Title: Re: KTM 640 - Dedicated thread
Post by: blauth on December 07, 2010, 07:08:18 pm
I have had mine for 5 months now, got it at 8000 km's, now done just over 12000 km's.  All dirt technical and dirt highways.  When I first took her offroad I did suffer from headshake, got a fright on some of the loose rutted sections.  I set all suspension/compression to default as per manual  She has been great since, done about 3000km's on her since the changes, no more unstable/unruly behaviour.  Perhaps try starting as I did, from default manual settings, go from there?  Whoever you bought the bike from, obviously set the settings up for their weight and riding style, it suited them, now you set it to suit you? I do not have any steering damper on.
Just a thought, I am not the most technical person, this advise came from Blazes and Runner and it really did help?   :thumleft:

I thought I would give a little feedback on my headshake problem:
I did the following:
- I set the suspension settings back to what the manual says is the default.
- I also set the preload on the back spring way soft so that the back of the bike sags quite a bit more thus reducing the rake.
- I binned the crappy sahara tyre and put on a knobbly (Dunlop something or other) that came off my yamaha WR450.

The head shake problem was pretty much gone however having said that, for peace of mind, I would fit a damper if I kept the bike. I have however regrettibly sold her (despite being very happy with it now) for other reasons.

Ooh, and if you haven't fitted a pipe on your bike, go out tomorrow and fit one. I fitted an FMF pipe and what a difference!!!!! Different bike.

Here's a pic:
(http://www.logical-dimensions.co.za/Pictures/IMG_1874 Compressed.jpg)