KTM LC4 (640) Thread Index

Discussion in 'Thumpers' started by meat popsicle, Jul 9, 2005.

  1. gunnerbuck

    gunnerbuck Island Hopper

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    Using the bushing shouldn't be a problem, maybe give it smathering of moly grease upon assembly... You will likley see a bit shorter lifespan from the bushing but it should last as long as a set of brushes...
  2. stumpy-ktm

    stumpy-ktm Adventurer

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    cheers mate , my thoughts are the same , the sad thing was there was nothing wrong with the original bearing , but a new one came in the kit so i punched the old one out ......if i found some bronze rod i could proberlly turn down my own bushing ....
    thanks
  3. skibum69

    skibum69 slave to gravity

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    Looks like you have a little winter on the go over there:lol3
  4. Dolly Sod

    Dolly Sod Red Clay Halo

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    Need some help.

    Replacing the front wheel bearings and seals on my 2002 640 Adventure. Bearings are coarse. Seals and bushing surface are shot.

    This is what I've got comparing the old parts (top) to the new parts (bottom)...

    [​IMG]

    The new bearings fit perfectly on the axle, the old bearings ride on a bushing which fits on the axle. New seals and bearings won't fit the hub bore.

    Any ideas on what I need to order to redo the front end? Anyone want to buy spacers, seals and bearings for a 2002 640 ADV?

    Thanks...

    FWIW, also ordered bearings and seals for the rear wheel, and everything looks right.
  5. christian

    christian Exchange your GPS Track!

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    Are you the first owner of the bike?
    if yes, did you do anything to the front wheel/forks?

    If you bought used, do you know about any changes to the forks/ front wheel?

    if my memory serves me well, the 02 adventure had a 20mm front wheel axle, and the bearing you have (old) are 26mm - so it looks like the wheel is not the stock one.

    The bottom bearing and spacers are the 20mm ones. for bike 2001-2002

    some bike in 2003 (sxc) still had the 20mm axle, but other (EXC/Adv) had the axle upgraded to a 26mm


  6. Dolly Sod

    Dolly Sod Red Clay Halo

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    I'm the 3rd owner. Just getting to know the bike. I'll give the previous owner a call and see what he knows.

    2003(sxc) seems promising. The seal is listed as 35X47X7 which are the dimensions of the seals I pulled off the front wheel.
  7. christian

    christian Exchange your GPS Track!

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    be careful what you order, I would measure your existing bearing and call cbrbearings.com

    you have some mix/match situation here, my not be safe to order from KTM
  8. Dolly Sod

    Dolly Sod Red Clay Halo

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    Yeah, I'm not going to do anything until I hear back from the previous owner.
  9. biensur22

    biensur22 Been here awhile

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    Why don't you do a reverse lookup. Check the part numbers on the seals/bearings you pulled from your existing wheel and cross reference them through some michrofiche (i know you can do it through munn-racing's interface accessed through KTM-talk). That might give you an idea what wheel you're dealing with and replacement parts.
  10. Dolly Sod

    Dolly Sod Red Clay Halo

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    Part number for the seals and bearings match 2003 250EXC, 450/525 sx, mxc, exc. Not sure about the axle diameter for those bikes, so I can't be sure if the bushings will work. :dunno

    I'll keep looking.
  11. gunnerbuck

    gunnerbuck Island Hopper

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    Looking at your old take out units, it appears to me that your bike has the recall front wheel with the Excel rim.... When they recalled the original wheel in 03 due to spoke breakage problems they replaced it with the wheel off the RFS bikes and made the adapter spacers for it to fit the 640 A...

    What you need to do is order a bearing and seal kit for a 03 KTM 450/525, even an aftermarket kit will work... You will then need to order the spacers through KTM : part #584 09 012 000... These spacers will take a couple of weeks to arrive as they are a special order item...
  12. juames

    juames Have Fun, Don't Die!

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    My '02 has the top bearings and spacers. Just bring the old bearings to a bearing shop and they can match them up for you, and clean up the spacers and re-use them...worked for me.
  13. Dolly Sod

    Dolly Sod Red Clay Halo

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    Yes it does have the Excel Rim.

    Thanks. :freaky



    Yep, I was thinking about cleaning up the spacers, or perhaps taking them to a machine shop and seeing what it would cost to machine them down and having a stainless slip ring made for the seal surface.
  14. gunnerbuck

    gunnerbuck Island Hopper

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  15. HydroDog

    HydroDog Been here awhile

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    Why not just go to your favorite bearing store and get a speedy sleeve to fit the seal area?
  16. juames

    juames Have Fun, Don't Die!

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    Anyone know if there is a water pump rebuild kit available, or do I have to order all the part separately?

    Planning on doing my first water pump rebuild on my '02, and not sure of what parts I need.

    :ear
  17. tdreyer

    tdreyer KTiM

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    Did you not look at the first page of this thread? It is the index for most everything LC4. Anyway, look here. First post gives you the parts breakdown. Bearings and seals can be had cheaper if you've a supplier near by. Just order 2 of everything so you'll have a kit waiting on the shelf for any future emergency or an inmate in need.:freaky
  18. skibum69

    skibum69 slave to gravity

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    have you checked your cam rollers while you're in there?
  19. juames

    juames Have Fun, Don't Die!

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    Haven't opened it up yet, but it's around 30,000kms now so its probably ready.

  20. enduro0125

    enduro0125 Sticks and Stones™..

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    Do it. :deal

    DAMHIK