Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => KTM LC4 400/610/640 & 690 => Topic started by: bonova on May 18, 2011, 09:54:16 pm

Title: KTM 640 - why so little info?
Post by: bonova on May 18, 2011, 09:54:16 pm
Just wondering..... why is there so little info on problems with this bike (on WD anyway)
Do they just not break, or are the owners not keen to tell?
I'd like anyone's feedback on their bike..... repairs costs, fuel economy etc......
Thanks  :thumleft:
Title: Re: KTM 640 - why so little info?
Post by: Mool on May 18, 2011, 10:04:58 pm
I think everyone just goes to ADVrider  http://www.advrider.com/forums/index.php
Title: Re: KTM 640 - why so little info?
Post by: the_BOBNOB on May 18, 2011, 10:07:26 pm
Just wondering..... why is there so little info on problems with this bike (on WD anyway)
Do they just not break, or are the owners not keen to tell?
I'd like anyone's feedback on their bike..... repairs costs, fuel economy etc......
Thanks  :thumleft:

big end bearings is to the 640 as steering head bearings are to the dakar - to be replaced every 25 000km  :peepwall:
Title: Re: KTM 640 - why so little info?
Post by: Dux on May 18, 2011, 11:09:10 pm

big end bearings is to the 640 as steering head bearings are to the dakar - to be replaced every 25 000km  :peepwall:

I disagree , I have personally seen these bikes with in excess of 50 000km , no issues at all .
However bikes that have been ridden at high speeds of 160+ for long distances are more prone to main bearing failure , and this I have seen with all makes of bikes not just the KTM's .
Title: Re: KTM 640 - why so little info?
Post by: michnus on May 18, 2011, 11:27:57 pm
Battery at angle under seat- rough road = kick start and new battery.
Late model 640 in EL ate big end bearings in 8000km.
Worst on fuel consumption from most 650's.
I think the engine is not regarded as reliable.
Google link  (http://lmgtfy.com/?q=ktm+640+problems)
http://www.horizonsunlimited.com/hubb/ktm-tech/ktm-640-adv-problems-list-9345-3
http://www.horizonsunlimited.com/hubb/ktm-tech/ktm-electric-start-problems-41819
http://www.thumpertalk.com/forum/archive/index.php/t-830206.html
http://www.thumpertalk.com/forum/archive/index.php/t-830206.html
Pity, the basic of the bike is a good d/s bike.

PS: Most owners still on the road not had a change to report back on the bike, the reason for the lack of info. KTM riders will never admit when they have shit with their bikeks :pot: :biggrin:

Title: Re: KTM 640 - why so little info?
Post by: Dwerg on May 19, 2011, 07:12:20 am
I bought a 2002 model with 33500km on the clock on Saturday. I've now done about 420 km on my first full tank and I haven't hit reserve yet (26 litres before you hit reserve). Also been riding it pretty hard so that's impressive. From what I can tell so far, the fuel consumption is somewhere between 16 and 20 km/l depending on how you ride.
Title: Re: KTM 640 - why so little info?
Post by: AntonW on May 19, 2011, 08:29:51 am
Just wondering..... why is there so little info on problems with this bike (on WD anyway)
Do they just not break, or are the owners not keen to tell?
I'd like anyone's feedback on their bike..... repairs costs, fuel economy etc......
Thanks  :thumleft:

big end bearings is to the 640 as steering head bearings are to the dakar - to be replaced every 25 000km  :peepwall:


that is BS, maybe on the older models
Title: Re: KTM 640 - why so little info?
Post by: Malibu on May 19, 2011, 08:36:17 am
Guess we have nothing to report.... anyway, I just ride and then every 500/600 or so kilo's I put some petrol in! 

Too busy riding to worry about stuff! 

It's a REAL adventure bike... strap your stuff on and go! 

I check my oil, lube my chain, and enjoy!

Once a month, I check that nothing has rattled off, which has not happened yet...
Title: Re: KTM 640 - why so little info?
Post by: Metaljockey on May 19, 2011, 10:25:10 am
I had a 2002 and used it extensively on off-road trips. I had really good times on that bike and I still rate it as the most complete package out the box. (I do not have any experience with the XT660Ten)

The problems I had was all possibly related to the vibration of that motor. Rev that baby on the centerstand and it runs around the garage like a rabbit.

When I have to do distance on tar, I like to be able to at least maintain a steady 140km/h. This unfortunately is exactly where the bike vibrates worst, so much so that I have to ride with my legs open to keep them off the tank and your hands loose all feeling. I hated it on tar.

The hooter bracket vibrated in half, the needle retainer washer vibrated away in the carb, I had 4 batteries go 'poof' in short succession, the float level continually goes out of spec. Even SW Motech gave up on the protection bars because they would just crack due to vibrations.

Some of the batteries going poof may have been due to wear in the starter and too great a load, with the lights that stay on during cranking.

Fuel consumption was pretty steady at 16-17km/l. Irritating when your mate on his clapped out Dakar consistantly gets 24km/l.

In my group of riding buddies there were 3 640's. Two blew their motors, a 2003 and a 2005.






That said, I am considering getting another one.

It has everything an adventure bike should have. Large tank, proper subframe, wind protection, good quality parts, carrier rack, light weight, good suspension and easy to use.

The weight, height and general ergo's makes it a pleasure to use in seriously technical terrain. And at speed over rough terrain it is sublime.

I have spent a lot of quality time on that bike and I have a very soft spot in my hart for it.

Title: Re: KTM 640 - why so little info?
Post by: DUSTRIDERS on May 19, 2011, 12:30:22 pm
MJ if you could put your Xchallenge engine in the 640 would you be a happy man?
Title: Re: KTM 640 - why so little info?
Post by: bonova on May 19, 2011, 01:09:48 pm
MJ if you could put your Xchallenge engine in the 640 would you be a happy man?

ahhh - that be the question  :biggrin:

thanks for all the info guys - interresting  :thumleft:
Title: Re: KTM 640 - why so little info?
Post by: michnus on May 19, 2011, 01:13:49 pm
MJ if you could put your Xchallenge engine in the 640 would you be a happy man?

We had this discussion and though a 1200 engine would be better, not?
Title: Re: KTM 640 - why so little info?
Post by: LuckyStriker on May 19, 2011, 01:24:09 pm
Do they just not break?
You wish :D

MJ if you could put your Xchallenge engine in the 640 would you be a happy man?
I wish (i could have that)  :)
Title: Re: KTM 640 - why so little info?
Post by: bonova on May 19, 2011, 03:37:24 pm
MJ if you could put your Xchallenge engine in the 640 would you be a happy man?

We had this discussion and though a 1200 engine would be better, not?

with shaft drive..... while we dreaming  :mwink:  :3some:
Title: Re: KTM 640 - why so little info?
Post by: Kaboef on May 19, 2011, 04:56:52 pm
MJ if you could put your Xchallenge engine in the 640 would you be a happy man?

Hey, this was my idea first.

My bank account number is:


 :biggrin: :biggrin:
Title: Re: KTM 640 - why so little info?
Post by: 2StrokeDan on May 19, 2011, 07:35:13 pm
Definitely a bit of a main bearing gremlin running through the line. But that is definitely the best ever ADV. package out of the box. 30KGS lighter than a 660Ten.
Title: Re: KTM 640 - why so little info?
Post by: goingnowherequickly on May 19, 2011, 08:10:16 pm
Love mine to bits...
MJ you forgot to add kickstart & carburetor to the list ... helps when you're 2 weeks away from a dealer...
good suspension, range , good brakes & GRIN FACTOR :ricky:
have to weld pannier racks from time to time ( looking to improve these a bit...)
Had a big end mishap at 29 K (Km) but this was my fault thru bad self servicing.. ::)
very complete package, although an aftermarket pipe is quite nice..
OK I'm a little bit biased  ;D


 
Title: Re: KTM 640 - why so little info?
Post by: Ball and Chain on May 19, 2011, 08:45:35 pm
It's too good.

So it's just boring :mwink:
Title: Re: KTM 640 - why so little info?
Post by: the_BOBNOB on May 19, 2011, 08:46:27 pm
Had a big end mishap at 29 K (Km) but this was my fault thru bad self servicing.. ::)

care to elaborate ???
Title: Re: KTM 640 - why so little info?
Post by: goingnowherequickly on May 19, 2011, 09:08:04 pm
lost a little spring & plunger in the draining tub....
DUH!!
 shouldn't have even bothered about draining that bit anyway...
4000Km later, testing a newly fitted pipe it went ...
My fault, found the missing bits after that in the old oil.. :-[
Cant blame the bike for that...
Title: Re: KTM 640 - why so little info?
Post by: buzzlightyear on May 19, 2011, 09:16:34 pm
The weight, height and general ergo's makes it a pleasure to use in seriously technical terrain. And at speed over rough terrain it is sublime.

I have seen MJ go up Katberg at speed on the 640 during the Hogsback Bash  ;D Even Ball & Chain saw it, and he still bought the bike  ;D
Title: Re: KTM 640 - why so little info?
Post by: African child on May 20, 2011, 07:34:05 am
Ek is fanaties oor my 640! Beslis seker nie almal se koppie tee nie, maar ek sal elke keer weer die slet kies....
Title: Re: KTM 640 - why so little info?
Post by: Doerengone on May 20, 2011, 08:19:43 am

Mine has 35,000km on at the moment. Only issues so far have been crashbars cracking (removed bars), and a clutch master cylinder that had to be replaced. Overall, a very complete bike, with superior brakes and parts in general. But the best is the suspension, which makes you grin whenever you leave the tar.

As a general precaution, I will be replacing inlet rocker bearing at the next service. In the longer term, the fitting of a ''new'' X challenge motor in the might be an option, I just dont know if it has been done yet.

As noted, ADV Rider has a comprehensive idex on the 640, with a wealth of info.
Title: Re: KTM 640 - why so little info?
Post by: Sprocketbek on May 20, 2011, 08:58:36 am
Mine is an 2003 model that I bought brand new in 2004.
It has 42000 km on the odo but I don't commute with it; just off road trips or maybe the odd trip into town or to Hermanus.

Left main bearing went @ 22500 km but I know why: I was riding at 160+ for two hours on tar trying to keep up with some 990's. Total repair cost was in the order of R 7000, there was no other damage to the crankshaft or case. Those motors are pretty tough in my opinion as I rode it for about 15 km with the most horrible noises coming out of it.

Other than that:
Clutch slave cylinder, master cylinder just kit.
Swingarm pivot shaft snapped when the needle bearings seized.
Front shock seals.
ALL the wheel bearings, as soon as one became dodgy.
Replaced all spokes with SS due to corrosion.
I'm on my third battery. The 2nd was a pirate and lasted 2 years, will stick to the ones from the agents.

As mentioned the biggest downside is vibration. My right hand often goes completely numb, mostly at cruising speed.
Title: Re: KTM 640 - why so little info?
Post by: Dwerg on May 20, 2011, 09:20:16 am
Mine is an 2003 model that I bought brand new in 2004.
It has 42000 km on the odo but I don't commute with it; just off road trips or maybe the odd trip into town or to Hermanus.

Left main bearing went @ 22500 km but I know why: I was riding at 160+ for two hours on tar trying to keep up with some 990's. Total repair cost was in the order of R 7000, there was no other damage to the crankshaft or case. Those motors are pretty tough in my opinion as I rode it for about 15 km with the most horrible noises coming out of it.

Other than that:
Clutch slave cylinder, master cylinder just kit.
Swingarm pivot shaft snapped when the needle bearings seized.
Front shock seals.
ALL the wheel bearings, as soon as one became dodgy.
Replaced all spokes with SS due to corrosion.
I'm on my third battery. The 2nd was a pirate and lasted 2 years, will stick to the ones from the agents.

As mentioned the biggest downside is vibration. My right hand often goes completely numb, mostly at cruising speed.


Mine also makes horrible noises but I took it to KTM and they recon it's just the normal noises  :biggrin:

Also need to replace fork seals but I knew that before I bought it. My spokes are also quite rusty. What does it cost more or less to replace?

I knew from the start that the bike would cost me a lot to maintain but I got it at a bargain price and love it so much that it doesn't really bother me
Title: Re: KTM 640 - why so little info?
Post by: bradleys on May 20, 2011, 09:28:13 am
I love my 640 ,it has 38500km ,has not let me down,I popped a fork seal on the way to the ec bash,had fun on the rough shit but she handled like a beauty.Yes top end is a prob,but when I travel long distanceI run her around 6th revs then will go to 75th revs for a bit just keep varing the rpm.I service the bike myself runs on castrol activo,I do ride her hard but she loves it. For the handle bar vibrations just stuff foam rubber inside the bars,helps a bit.

I am in a bit of dilema do I sell my baby and buy a 990 or keep the 640?
I have had no shit ,only chains ,sprockets  and service ,yes need to change therockers.
Title: Re: KTM 640 - why so little info?
Post by: Sprocketbek on May 20, 2011, 11:16:01 am
Mine also makes horrible noises but I took it to KTM and they recon it's just the normal noises  :biggrin:
No, no, you don't understand what real noise is till you've heard a main bearing go.

My spokes are also quite rusty. What does it cost more or less to replace?
I've been looking for SS spokes for a long time but everybody just shrugged or didn't answer my E-mails. I ran into Vark and he told me Mario from Dirt Riders in Killarney Gardens did his and he's very happy. Now I am too.
Costs: About R 1000 for each wheel's spokes. He charged R 480 to lace, I could have had it done cheaper elsewhere but I chose to support the guy that delivers the goods. Also I have the aluminium coloured DID rims, they came with thinner spokes so all the holes had to be drilled out slightly. Another (optional) R 700 to have both of the rims anodized brought the total to R 3700 tax incl.
Title: Re: KTM 640 - why so little info?
Post by: the_BOBNOB on May 20, 2011, 05:12:06 pm
Just wondering..... why is there so little info on problems with this bike (on WD anyway)
Do they just not break, or are the owners not keen to tell?
I'd like anyone's feedback on their bike..... repairs costs, fuel economy etc......
Thanks  :thumleft:

big end bearings is to the 640 as steering head bearings are to the dakar - to be replaced every 25 000km  :peepwall:


that is BS, maybe on the older models

did your bike not try to push the cam and rockers out the breather pipe ???

dot get me wrong i love the 640 - but reliable it aint .
Title: Re: KTM 640 - why so little info?
Post by: AntonW on May 20, 2011, 08:35:30 pm
I always thought that the big end is at the bottom of the motor and the cam at the top. The inlet rocker seized, not the big end or main bearings. This is well documented I am told it Is from running at high speeds for long periods of time. The thing to remember that it is a race type motor so needs tlc.
 
Title: Re: KTM 640 - why so little info?
Post by: domstes on May 20, 2011, 09:11:03 pm
Still and to this day the only bike off the shop floor that can do the Dakar unchanged. Not suspension or engine changes. Only extra fuel and water containers.
Many have done it.
Title: Re: KTM 640 - why so little info?
Post by: bradleys on May 23, 2011, 11:11:03 am
Best dual sport ever :thumleft: