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Old 03-22-2012, 07:12 AM   #1
izom OP
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Location: LandofArnoldS./Vienna
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Pissed lc4 adventure 640 massive start problems

-it began about a year ago- my adventure wont start easy- e-starter passed out when cold- so i manly kickstart the bike when cold!
then there was the bogging thing when i was driving gettin worse also!

-so i mounted a NEW battery last autumn- NO better startin when cold! means NO starting at al- still had to kick the bike!
always felt like battery is to weak to turn the engibne!

- so this year i dismounted the CARB- cleaned it - set the floatbowl correct- cleaned the choke-
changed the spark - adjusted the valves-

now it starts NOT at all- even not with the kickstarter !!!!???

im really pissed...

tried to start it with batterycharger on- only makes horrible clanking noises!?

...yeah and it backfires!!??

http://www.youtube.com/watch?v=pYcaes1jBHQ&list=UUAdkqPt1i72vPN_OVPSRKOA&index=1&feature=plcp

help me please before i kick the bike in trash!!

peter/europe
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Old 03-22-2012, 08:57 AM   #2
gunnerbuck
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Hi Peter,

That horrible racket sounds like it's coming from your starter clutch... There are likely 2 problems that come in to play here: The first is that your auto decomp is not working properly and because of this it puts more stress on the starting system... Without the compression relief the decomp gives, the starter can barely turn the engine and after a while the starter clutch will start to slip in the flywheel drum creating a noise similar to whats in your video... Continued use in this condition will ruin the starter drum as well... This thread may help:http://www.advrider.com/forums/showthread.php?t=222515

Try turning the engine over with the manual decomp lever pulled in and see if it turns easier and is quieter...

Also make sure everything is working properly with the carb and it is not putting too much fuel to the engine... If you had the fuel pump off make sure the hoses are connected properly...

Also, were your valves adjusted on the right stroke?

gunnerbuck screwed with this post 03-22-2012 at 10:06 AM
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Old 03-23-2012, 07:49 AM   #3
izom OP
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Pissed

Quote:
Try turning the engine over with the manual decomp lever pulled in and see if it turns easier and is quieter
..yes it does- without noise and problems- but as soon i let the decomp.lever out - problem is here...!

valves should be ok!- ...but who knows!?

what ireed in the linked tread- people could kick the bike even when the starterclutch is gone!??

but i cannot kickstart mine anymore!??

try some things out on weekend- well see....
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izom screwed with this post 03-23-2012 at 08:07 AM
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Old 03-23-2012, 08:57 AM   #4
gunnerbuck
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For sure, your starter clutch needs repair... Your auto decomp cam is likely shot as well but you can use the manual lever to the same effect...

Do you notice if the floatbowl drain tube on the bottom of the carb is weeping a bit of fuel?
Try hooking a fuel line directly to your carb bypassing the fuel pump to rule it out...

Also go through your wiring and check for breaks in the shielding or shorts... Pay close attention the the wires under the dash and the wires around the CDI under the right side cover...

gunnerbuck screwed with this post 03-23-2012 at 10:36 AM
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Old 03-27-2012, 02:03 AM   #5
izom OP
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Thumb

hi gb-

good news- i could start the bike with the kicker!!!

cleaned the spark- valves were ok- played with choke- as NO choke- and th bike starts and runs!?!!

-so its still too rich??- i adjust the fuel/airscrew a bit.

as for the e-starter- iw ill have alook at this later- try a new battery also next time before i dismount something!

thanx so far

pete
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Old 03-27-2012, 06:42 AM   #6
gunnerbuck
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Hi Peter,

How many KMs on the bike? Richness could be caused by worn parts inside the carb, in particular your needle jet and jet needle, also the vacuum slide and slide guide should be inspected for wear as well....
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Old 03-27-2012, 03:11 PM   #7
Alik
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Peter,

You could open the valve rocker cover and see the worn autodeco system for yourself - and maybe you are lucky enough to just change the spring in the autodeko. But maybe you will not be so lucky - judging on your other problems the bike already developed some "worn out" symptoms you have to take care about.
I support Gunnerbuck on the wires - I would look into the „-„ wire leading form the battery to the frame first. It sometime works wonders.
Then the clutch sprague - it doesn’t cost a fortune, ca. 70 EUR - if you continue to use the starter button the while it is broken then you colud probably end with more borken parts including the freewheel itself. You need a magneto extractor and possibily a magneto holder to do it right (r you could open the clutch cover too and hold the other side of the crank with a open box wrench of suitable size.
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Old 03-28-2012, 12:15 AM   #8
izom OP
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Laugh

Quote:
the vacuum slide and slide guide
-yes this things were worn!- replace them next time! as theire not available immediatly by my dealer and i need to make the bike ready for 3day easter drive!!

greetz
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Old 03-30-2012, 12:53 AM   #9
bmwktmbill
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Quote:
Originally Posted by izom View Post
hi gb-

good news- i could start the bike with the kicker!!!

cleaned the spark- valves were ok- played with choke- as NO choke- and th bike starts and runs!?!!

-so its still too rich??- i adjust the fuel/airscrew a bit.

as for the e-starter- iw ill have alook at this later- try a new battery also next time before i dismount something!

thanx so far

pete
Do you have some slack in this cable...it should not be too tight or the choke is always on.
bill
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The faster it goes the faster it breaks.
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Old 05-08-2012, 01:57 AM   #10
izom OP
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Question

update-

carburator - replaced all worn parts incl. needle, vacuum slide etc.-

bike runs- no bogging anymore- starts with kickstarter -cold, warm-

new batterie, e-start still not working-

check e-start itself!- looks and smells burned!?

let it check from electric-shop if strong enough!?

NEXT STEP- look the f.in starter clutch!

do i have to drain oil- or can i just lay bike on left side???

reed somewhere to open clutch-cover??
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Old 05-09-2012, 09:49 PM   #11
bmwktmbill
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Starter looks like it willwork.
Starter clutch is on the right sie of the engine.
If you lay it over you shouldn't lose oil.
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.
Bill Shockley
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Old 10-02-2012, 05:31 AM   #12
izom OP
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Thumb start problems

...to clear this up-

after a headfailure this summer i had to repair and change the rollerbearings and cam- after that it worked/started!

so my autodeko on the old cam was the problem!!! it didnt work anymore!?

now she starts up again fine!

greetz
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