640 LC4 gasket set differences?

Discussion in 'Thumpers' started by moto_psycho, Feb 22, 2013.

  1. moto_psycho

    moto_psycho Nob.

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    Hi guys, I just ordered a gasket set, and the eBay ad said it fit my bike along with various other models, but they are not listed on the Athena site. My bike is a 2004 640-E

    http://www.athenaparts.com/eng/models/view/2544-section-93/ktm-lc4-e-640-enduro

    I have gotten the 1999-2002 kit, now, after a tiny bit of reading, I believe this kit has a thicker base gasket. Are there any other differences I need to be aware of, should I send it back for a replacement?
    #1
  2. laramie LC4

    laramie LC4 crash test dummy!

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    yours is the new head while your gasket set is the old. there will be several diff in the top end, the bottom should be good though. yes, the base gasket will be a diff thickness. make sure to check carefully.

    laramie :beer
    #2
  3. Seikkailu_R

    Seikkailu_R Been here awhile

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    Actually some parts catalogs claim that oem 101,3mm (ktm 58330036000) head gasket is used on all 625cc models, and even on some older and smaller models...

    On cylinder base gaskets there is more variation, different thicness for different engine sizes and models.
    0,5mm and 0,7mm for 625cc, at least?



    #3
  4. bmwktmbill

    bmwktmbill Traveler

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    Being ignorant I used the thick base gasket on my '02 which should have the thin one...oops...well it's running fine 10K miles later.

    bill
    #4
  5. gunnerbuck

    gunnerbuck Island Hopper

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    The 02 is supposed to have the thicker gasket, if you had to ream out the alignment dowel holes then you installed the thinner one by mistake... The low flo engines run a .7 VS the Hi Flo going with a .5...
    #5
  6. gunnerbuck

    gunnerbuck Island Hopper

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    As mentioned in the above posts, the 02 base gasket is indeed thicker which isn't all bad, the problem is the alignment dowel holes will be much larger on the 02 gasket and will not fit tightly... I plan on running the same gasket on my 03 bike to mellow the compression slightly and my solution to make the dowel fit is to cut out tiny donut gaskets to fill in the gap around it... The case gaskets should pretty much work but you'll not get a clutch slave gasket with the early kit but the head gasket WILL fit..

    I have noticed a huge price difference between the pre 03 and the post 03 Athena gasket kits... I think if I order another I will order the early model kit and save some bucks...
    #6
  7. bmwktmbill

    bmwktmbill Traveler

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    Gunner's right, I had to enlarge the dowel holes to make the gasket fit so I suppose in a pinch you could....
    bill
    #7