KTM 640 Adventure, what spares to carry?

Discussion in 'Thumpers' started by bmwktmbill, Aug 7, 2005.

  1. bmwktmbill

    bmwktmbill Traveler

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    Hi everyone,
    Headed to Seattle to p/u my new to me '02 LC4 Adventure. I plan to ride around the westren USA for 3 or 4 weeks getting to know the bike. I want to put together a list for spare parts to carry when traveling. Since I am headed out of the country next year these parts will form the basis of a permanemt kit to be carried for general overland travel. Any ieas would be appreciated. If a list already exists just point me in the right direction.
    Thanks, Bill Shockley, Tomahawk, WI.
    #1
  2. markjenn

    markjenn Long timer

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    I wouldn't go overboard, just the usual tire repair stuff, a spark plug, and a clutch cable. Also the general repair stuff: duct tape, electrical tape, tie wraps, bailing wire, strapping. etc. There are some good toolkit threads here - do a search.

    Unless you have complete trust in the PO and the state of the bike, I'd go over it carefully before you leave, paying particularly attention to fasterners, chain, sprockets (including checking the tightness of the front sprocket bolt), spokes, wheel bearings, and battery condition. I'd also service the air filter and do an oil change. If you find problems, it will be a lot easier to fix them in Seattle then in Winnemuca.

    - Mark
    #2
  3. Drif10

    Drif10 Accredited Jackass

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    02?

    Clutch cable. Then swap it for the hydro unit when you get home.
    #3
  4. Drif10

    Drif10 Accredited Jackass

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    Make your life simple: Creeper will pick you up, take the bike to his shop, and all you need to do is sit there and listen to him babble as he tweaks EVERYTHING on the freaking bike.

    It's much easier to do it this way. :lol3
    #4
  5. 2whlrcr

    2whlrcr gooligan

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    I'm not sure I'd follow this advise. Clutch cables are cheap and easy to replace, especially if you preroute it next to your existing cable.

    If you break your hydraulic line you're screwed. It won't break with normal use like the cable might, but you can snag it on a branch, rock, etc... or bust a fitting in a crash. A slim chance, but it's the oddball stuff that usually ruins your day.
    #5
  6. Loadedagain

    Loadedagain making chips

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    i agree. say no to hydraulic. more pain than they're worth.

    run an extra cable alongside the cable that's in there. that way it only takes a couple minutes to change it if there's a problem.
    #6
  7. Drif10

    Drif10 Accredited Jackass

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    3 cables in a year, hydro has worked perfect last two years.

    You figure out what works for you.
    #7
  8. Loadedagain

    Loadedagain making chips

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    if you had issues with cables and the hydro has been good... you did the right thing... for you.

    i had a hydro on an exc. let me down a couple of times with dumped oil.

    still have the original cable in my 640 after more than 24,000km. i have a second one in there ready to roll and a spare in my parts box... it has been good.

    all my other cable clutch ktm's have been goo also. only once broke a cable (on my 300exc) when it fell out of the trailer on the way to squamish. not the cables fault.

    lotsa guys love the hydro clutches though.. so :dunno
    #8
  9. dagwood

    dagwood Banned

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    pack of 1157 tail light bulbs.
    other than that. :dunno...never needed a spare nuthin.
    it's not like it's a jap bike.
    :scratch

    and only changed the clutch cable once...at 1,200 miles. I'm at 12,000+ and the cable looks like new. I think once the edges are worn off the mount and the new cable is lubed your good to go. I wouldn't sweat it If it's been changed once already.
    #9
  10. matey peeps

    matey peeps Bead Buddy

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    If your 02 is anything like my 02, pack a spare ass. Mine is killing me after 100 miles, but I don't quite have the coin for a bling-tastic Renazco seat. :cry
    #10
  11. Airhead

    Airhead More human than human

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    I second the spare ass...

    :tush
    #11
  12. crankshaft

    crankshaft Guns are for pussies

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    I'll third that motion.......
    I'm still sore from a long ride in Maine 2 weeks ago.:lol3
    #12
  13. Drif10

    Drif10 Accredited Jackass

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    You speaketh da trooth. :cry

    But guess what I got now. :ricky

    Renazco good. Stock bad.
    #13
  14. Doc_Busa

    Doc_Busa Been here awhile

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    Where does one find one of these mythological ass-savers???
    #14
  15. dezracer

    dezracer Been here awhile

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    and dont buy a stock clutch cable replacement.But a motion pro cable.Trust me on this one!You can SEE the difference just looking at them.
    #15
  16. G.Kennedy

    G.Kennedy ...

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    Fourth. For your western trip, maybe take a piece of dense 1/2 to 3/4 inch foam, may be ... 12" x 12" and duct tape it to the seat.

    I hear good thing about Renzaco, but Rocky Mayer made a great seat for my BMW, I gonna have him make me a more petite dirt version for the 640.
    #16
  17. Ian640

    Ian640 Been here awhile

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    Hi dezracer. Do you have a part number for the Motion Pro cable for the LC4?

    Thanks in advance.
    #17
  18. Spokes, lots of spokes. Front only, I'd say. They break all of the time on my '02, although not usually if I am touring, and something to cut them in half with, like a knife with a hacksaw. I just rebuilt the wheel with new ktm oem spokes which are a much bigger guage which shows there was a problem. I don't recommend a rebuild as it is easier to buy a new wheel if you start breaking them often.


    On your trip I would squeeze them together periodically to see if they are loose and broken. I ziptied the brake side ones together so they can't get into the caliper. It looks unlikely that that would happen but somebody posted here that it did and locked there front wheel at speed.


    I never had a clutch cable problem, but I carry a spare because of what people say on this list. That main shaft bearing is worth changing as mine just blew up. Not a roadside fix.
    #18
  19. Reformed DucFlogger

    Reformed DucFlogger Inventor Of The Wheel Mk2

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    1. When you get the bike home, settle down with a cold one and some shade and strip all the bodywork, tank, etc off the bike with JUST the included toolkit. Then make a list of any tools needing to be turned into reinforcement for that new concrete step and thus replaced with good ones. Also which ones are missing.

    2. Bear in mind the tool kit's 6,8,10mm sockets will NOT work with a noral 1/4' drive ratchet - only a hex key (e.g. the blue handled one - great tool)

    3. Replace as many of the OEM 6mm bolts with stainless, etc as you can - the existing ones are SOFT. Combined with KTM's wax-like factory threadlock, this can result in some ugly curbside bolt removals. Be VERY careful around the rear rack bolts and the kickstand/centerstand bolt.

    4. Assortment of spare 6mmx1.0 hex bolts, couple of washers and posilock nuts.

    5. Spare shift lever - or do the KTM Sommer recomended trick of drilling a 'break' hole in the lever and a second threaded hole on the shift linkage side of the first 'design to break here' hole to accept a long 6mm bolt as a makeshift emerg shift linkage. Work takes 20 mins and simple as hell. Do a search here for a pick on the issue.

    6. DO NOT go by the KTM manual re" bolt/nut sizes when building a tool kit - manual notoriously wrong. Front and rear axle nuts are 27mm NOT 24mm, etc.

    7. Taking tank off with 13mm wrench a PITA. A 13mm long reach socket and driver if you have room.

    8. Husky (HDepot) sells a neat mini 1/4'drive rachet/screwdriver combo. Bought it the other day on a lark for bike and used it yesterday. Nice and small, handy , strong and could be attached to a key ring (sans sockets of course).

    9. The usual duct tape, etc.

    10. Bear in mind that you have a bike that uses metric fasteners and threads (obviously) which may be very tough to get replacements for, or a tap done for in small town USA - so be a little overly cautious re: spare/odd KTM-specfic bolts, spacers, etc. Hell, finding a 6mmx1.0 tap or bolt in a local hardware store in Canada (metric) is tough - construction trades are still on SAE.

    11. The 650 battery is infamous for being weak - small set of jumpers will get you a boost from any car/bike/go cart/lawnmower around.

    12. Might want to carry some spare jets and jet changing screwdriver. The BST jets are tough to find at the local generic bike shop if you lose one, etc., after a motel parking lot jet change or cleaning the carb internals.

    A lot of bike shops, including KTM dirt bike dealers don't seem to carry them as the dirt bikes now are mostly flat side carbs. Hate to be holed up in ButtHole Ala. for a week waiting for a $0.10 part.

    13. On jets: remove and replace them (with spares on hand) ONCE while at home before trip. The jets seem to be installed by Austrian arm-wrestling champs and can be a bitch to get out in good shape the first time.

    14. Fuel filter (doing this myself). The bike doesn't have one. Why? Good question.

    Blah, blah, blah....
    #19
  20. Loadedagain

    Loadedagain making chips

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    :wave heya... um... the 27mm hex nut on front and rear axles are 24mm threads...
    #20