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Old 03-29-2015, 11:35 AM   #1
chris1576 OP
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Joined: Mar 2014
Location: Jesmond, North of Hadrian's Wall, England
Oddometer: 7
2001 640 adv

Dear Agony Aunt
My adv lives outside under a cover in NE GB. It's Winter going on Spring now.
He's not happy unless I start him every day.
If I don't, he gets all sulky. Consequently I've bought him an optimate. He seemed OK with this.
Yesterday I started him, fine, ticking over...
Went out a few minutes later for a trip, he's pissing petrol from carb overflow, would not rev past tickover without choke. I thought sticky carb float, I thought bowl needs a beating with large screwdriver, maybe a one off? This seemed to do the trick and it's fine now.

I trusted a local Euro specialist to change the oil a while back. Clutch dragged real bad. He started pissing oil out of the airbox overflow. They took him back and sorted it and told me the level should be checked with dipstick screwed out? Clutch still drags. In fact the lever was real slack when I picked up, like tech had been practicing wheelies?

I'm thinking I should do things myself. I've done a few rebuilds on old Brit stuff. Between this site and You-tube I should be ok?

...but....

I've seen a Honda 650 TransAlp with all the gear for decent money, close-by - just replacing consumables without surgery...

If he sees me writing this he may never start again!

Help!?

chris1576 screwed with this post 03-29-2015 at 12:02 PM
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Old 03-29-2015, 11:54 AM   #2
Navin
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Clean the carb.
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Old 03-29-2015, 03:16 PM   #3
javahitman
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Its like breaking up with a good looking high maintenance chick and getting a fat girlfriend instead. It will be easier on the wallet but not same in bed


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Old 03-29-2015, 06:39 PM   #4
Umarth
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might also need to change the o-ring of the clutch master cylinder. Could be the reason the clutch is not disengaging fully.
You can use the same o-ring as the one behind the counter sprocket. 50cents fix and 1hrs worth of work.
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Old 03-29-2015, 06:57 PM   #5
dhally
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Quote:
Originally Posted by Umarth View Post
might also need to change the o-ring of the clutch master cylinder. Could be the reason the clutch is not disengaging fully.
You can use the same o-ring as the one behind the counter sprocket. 50cents fix and 1hrs worth of work.
The 2001 had a cable clutch. Same idea, it could be the cable itself is bad. I agree about changing bikes. The KTM is a hi performance machine, need a twin to outdo it.
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Old 03-29-2015, 07:03 PM   #6
Umarth
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Originally Posted by dhally View Post
The 2001 had a cable clutch. Same idea, it could be the cable itself is bad. I agree about changing bikes. The KTM is a hi performance machine, need a twin to outdo it.
That's a very relevant fact! lol
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Old 03-29-2015, 08:15 PM   #7
bmwktmbill
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Pull the carb, clean and rebuild it, then run the bike and adjust the clutch if it needs it after a good run in. It's almost impossible to break the clutch but they do get sticky if they sit.

Yes you check the oil with the dip stick screwed out. It's in the owners manual...if you don't have one just say.

It and a workshop manual are available through us for free.

Could someone help with the link?

bill
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The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 03-29-2015, 08:16 PM   #8
bmwktmbill
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Pull the carb, clean and rebuild it, then run the bike and adjust the clutch if it needs it after a good run in. It's almost impossible to break the clutch but they do get sticky if they sit.

Yes you check the oil with the dip stick screwed out. It's in the owners manual...if you don't have one just say.

It and a workshop manual are available through us for free.

Could someone help with the link to the drop box?

bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 03-30-2015, 04:37 AM   #9
MSH
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Quote:
Originally Posted by javahitman View Post
Its like breaking up with a good looking high maintenance chick and getting a fat girlfriend instead. It will be easier on the wallet but not same in bed


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Totally.
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Old 04-07-2015, 12:50 PM   #10
chris1576 OP
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Location: Jesmond, North of Hadrian's Wall, England
Oddometer: 7
Question trouble shooting

So, having resisted the charms of the prospective fat girlfriend (transalp), yesterday I'm having a ball, blatting around the backroads of the North Pennines on the 640 adv. A fun filled 100 miles or so, sweet as a nut.

Later I start the bike and lose my footing moving it off the drive. It falls sideways and stops, small pool of petrol from the overflow.
Since then it has failed to start despite numerous attempts.
C'mon this is an adventure bike, meant to be fallen off... not some sulky drama queen.

Ho hum, out with the spanners tomorrow and follow the won't start guide in the handbook unless, anyone has any similar experiences and tips?
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Old 04-07-2015, 08:06 PM   #11
dhally
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Bill said it 2x . CLEAN THE CARB. Pain in the arse but necessary. Impurities in the petrol condense over time and plug up the fuel passages. Tipping over moves the bits of gunk around, blocking different passages.

My xr400 would stall going up a steep hill. Finally quit running completely out on the trail. A field carb cleaning revealed a chunk of gunk plugging the main jet.
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dhally screwed with this post 04-07-2015 at 08:15 PM
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Old 04-08-2015, 12:22 AM   #12
chris1576 OP
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Location: Jesmond, North of Hadrian's Wall, England
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talking of xr's

Being pissed off with the ktm, I dragged my '99 Honda xr250r out of my dad's garage yesterday, where it's been hiding for a couple of months, and it started first kick. Now that's reliability...
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Old 04-08-2015, 04:04 AM   #13
Navin
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Yes. Well known fact Honda has a special extra reliable carburetor that prevents fuel from going stale.

Buy another Honda.
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Old 04-12-2015, 05:31 AM   #14
chris1576 OP
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Normality

Anyway

Off with the tank etc. Good spark etc. Then I see the problem. I thought I'd heard a pop when the bike went over. Maybe a backfire.

The carb had popped out of the rubber head manifold. The head and carb don't line up too well. Slackened clips and did my best.

Back together, running nice. More blatting around the North Pennines.
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Old 04-12-2015, 11:11 AM   #15
chris1576 OP
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Location: Jesmond, North of Hadrian's Wall, England
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Carb is fine, Bike is fine. From now on I do my own work.
F*** the P***T**ing F***ing Euro F***ing specialist
Kind regards,
Chris
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