KTM LC4 (640) Thread Index

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

  1. atomizer

    atomizer Be here now

    Joined:
    Jan 16, 2010
    Oddometer:
    479
    Location:
    Dixon, New Mexico
    Hey folks,
    When my 2006 640 Adventure is on it's center stand and I grab the rear wheel, there is a little bit of play in the Swing arm.
    My local shop quoted me $800.00 to fix the problem. Seems rather steep to me.
    Is this a job I can easily do myself or is the $800.00 quote there for a reason?
    Any help is appreciated. About to do the TAT and dialing in the bike.
    :freakyAtom...
  2. Kawidad

    Kawidad Long timer

    Joined:
    Jul 9, 2005
    Oddometer:
    5,683
    Location:
    Central Coast, Cal
    Wow :eek1 That sounds really high. Everybody's mechanical skill and comfort levels are different, but normally it is a job that can be done with the normal garage tools and only minor skills. :evil
  3. atomizer

    atomizer Be here now

    Joined:
    Jan 16, 2010
    Oddometer:
    479
    Location:
    Dixon, New Mexico
    My jaw hit the ground when I got the quote...

  4. beek-02

    beek-02 blazing a trail

    Joined:
    Sep 10, 2009
    Oddometer:
    113
    Location:
    California City, Ca
    Parts are probably about half that cost or more based off msrp that the ktm shop will probably charge. If you order online from powersportswarehouse.com or munnracing.com it will be less. The reason I suspect the quote to be as high as it is, I'd because they quoted you to change the swingarm bearings and sleeves, the linkage(cheaper to buy linkage with new bearings than buy bearings and replace them in your old linkage), and the bearings in your frame that the dog bones connect too. Any or all of those bearings can be the cause. The suspension link is just under $200 and swing arm is just under a $100. I'm not sure the cost of the link bearings in the frame. Also they maybe changing the shock hiem. If you can isolate which bearings are causing the issue it will be exponentially cheaper. You should be able to replace pretty much all of the bearings yourself with a vote and the right combination of sockets. As for the link bearings I'm the frame it might require some creative solution with a combination of threaded rod, washers, and sockets? I have the same problem and replaced the swing arm bearings for it, $80 later I had exactly the same results. Good luck let us know which route you go.

    Beek

    Sent from my SCH-I535 using Tapatalk 2
  5. Baggi'tard

    Baggi'tard Assventure rider

    Joined:
    Sep 20, 2006
    Oddometer:
    1,554
    Location:
    Farmhouse Inn, Tellico Plains, TN
    thanks, saw it on KTMworld.com too, just was hoping to not pay more for shipping than the part.. oh well. Nothing like having three motorcycles with no local dealer support..
  6. ChuckHazzard

    ChuckHazzard Registered Lurker

    Joined:
    Mar 27, 2005
    Oddometer:
    1,842
    Location:
    The corn state,11 curves in 318 miles (Iafalls IA)
    Gentlemen,

    The CS seal has been replaced. Was a smashed o-ring.

    [​IMG]

    [​IMG]
  7. Sparrowhawk

    Sparrowhawk Long timer

    Joined:
    Sep 26, 2005
    Oddometer:
    3,008
    Location:
    Eastern Washington, USA


    This is the kit I carry anytime I ride. I have assembled these tools over time with the intent of keeping it light and compact while still including everything needed for repairs short of a top end job. It handles all the normal maintenance tasks with the addition of a feeler gauge and "Creeper straw" for valve adjustments.
    • Cut off 5 mm hex key (valve covers)
    • Hex drive assortment: 1/4" square drive hex soocket, 4, 5, 6, & 8 mm hex; 8-10 flat (short & 3 1/2"), 5-6 flat, P1, P2 (short & 3 1/2")
    • CRKT mini knife
    • Sockets: 6, 8, 10, 13, & 19mm
    • 1/4" to 3/8" adapter
    • Thin wall 18mm spark plug socket (Allen brand fits the LC4)
    • 1/4" flex handle
    • 1" & 3" 1/4" drive extensions & universal
    • 5 1/2" long X 3/4" cheater (conduit)
    • Open end combination wrenches: 8/10, 10/11, 10/13, 14/17
    • KTM pliers
    • KTM axle wrench
    I use a 1/4" drive because it is sufficient for anything that isn't put on wrong. I also carry: a couple of 8 1/2" tire irons, patch kit, and spare 21" tube in a fender bag for flats; a bicycle pump strapped to the top of the forks; spare clutch handle & cable; assorted cable ties; and a length of fence wire.

    For multi-day trips I include a small multi-meter, electric tape, portable butane soldering iron & solder, 12 g wire, fuses, epoxy stick, chain tool, tow strap, spare shift lever, assorted nuts & bolts, spare head & tail light bulbs, and Locktite. I keep a copy of the wiring diagram on my smartphone.

    [​IMG]

    [​IMG]

    [​IMG]
  8. Young-Gun

    Young-Gun KTM Tragic

    Joined:
    Dec 6, 2005
    Oddometer:
    1,227
    Location:
    Brisbane, Australia
    Try going to a different gym? :D
  9. TexasDirt

    TexasDirt Adventurer

    Joined:
    Jun 20, 2012
    Oddometer:
    29
    Location:
    Houston, TX
    I had similiar symptoms recently. I rejetted, cleaned the carb, opened my air box, you name it!
    Ended up being a frayed wire that would depending on how my arse was positioned on the seat, make connection or lose connection! Things are not always what they seem. My carb was fine but now I have much more HP!!
  10. bmwktmbill

    bmwktmbill Traveler

    Joined:
    Jul 16, 2005
    Oddometer:
    5,610
    Location:
    Traveler
    There is a small screen in the fuel inlet pipe that could be partially plugged.You could try checking that before ripping the carb off.
    bill
  11. dnrobertson

    dnrobertson Big Bike, Slow Rider

    Joined:
    Jun 30, 2008
    Oddometer:
    1,003
    Location:
    Frankston, Australia
    Along those lines, how about the filter on the actual fuel tap in the tank. Take the hose off the fuel tap and see how much flow you are getting there?
  12. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    3,941
    Location:
    Rotoiti, North Is, New Zealand
    Kinked fuel line is another one to check for before pulling the carb.

    Cheers
    Clint
  13. rtwpaul

    rtwpaul out riding...

    Joined:
    Feb 7, 2011
    Oddometer:
    3,354
    Location:
    round the world
    PM me if you want one, took mine off and won't be needing it anymore, just pay the shipping and its yours
  14. dolphins13

    dolphins13 orange rules

    Joined:
    Jan 7, 2012
    Oddometer:
    138
    Location:
    spo wa
    Hard to fix a problem that fixes itself? When it dies on me, then I mess

    with it on the side of the road hoping it will start again. It dosnt start so I

    truck it home. Wont start in truck either. When I get home it fires up and

    I cant fix what aint broke. Three times in a row this has happened. After

    the 1st time I bravely took it for a 10 mile or so ride and it was perfect.

    next week it dies when I leave the gym again? and a week later does the exact

    same thig. Right now it starts and runs great, trick is to get it broke

    down at home? How does the ride home in truck fix it? Im really stumped

    on this one? gonna wear out my kickstarter or kill my battery on the side

    of the road if this continues. Its what I get for bragging how my bike

    always runs perfect? It used to. :eek1
  15. Dolly Sod

    Dolly Sod I want to do right, but not right now

    Joined:
    Aug 18, 2003
    Oddometer:
    15,281
    Location:
    Richmond, Va
    You're going to have to figure out a way to check spark next time it happens. Need to whittle the problem down to electrical or fuel related.
  16. ChrisC

    ChrisC Amal sex?

    Joined:
    Feb 25, 2003
    Oddometer:
    6,320
    Location:
    Prescott, Arizona USA Earth
    Make sure the fuel tank is properly vented to atmosphere... :deal
  17. overlandr

    overlandr Dystopist

    Joined:
    Nov 30, 2003
    Oddometer:
    5,929
    Location:
    Sydney
    Hey Dolphins13, what have you done to address the wiring harness/loom? Your bike is older so there's a good chance that there is some wear on the insulation.
  18. Beta450

    Beta450 Been here awhile

    Joined:
    Nov 26, 2010
    Oddometer:
    153
    Location:
    El Centro, Ca.
    Carry a can of starting fluid and if the bike acts up again spray some iin the air box and if it fires up then it's a fuel problem. If it does'nt then it is a electrical problem.
    It's just a quick method that I use to help find a problem.
  19. DolphinJohn

    DolphinJohn Caveman

    Joined:
    Mar 17, 2007
    Oddometer:
    4,014
    Location:
    Nature Coast, Florida
    2000 640 Enduro with the 18 liter tank. I had replaced it (fuel cock) a couple of years ago for the same reason.

    I just had the tank off, drained and cleaned (for another issue) and got everything back together and the damn thing would not stop dripping in the "on" and reserve positions.

    I took it apart several times and the o-ring looked good. If I put pressure upwards on the dial it would stop.

    Finally I tried taking the little spring out and it is now dry as a bone. Doesn't seem to be any problem not having it in there, other than a lack of feeling the notch at the "off" position.

    Just FYI if anyone has the same issue.

    .
  20. Nokmuay

    Nokmuay Plan B Specialist

    Joined:
    Aug 10, 2007
    Oddometer:
    533
    Location:
    South Western Ontario, Canada
    hey Guys!!!
    just curious. What are you all using for sproket set up? I had purchased this 2005 640 adv and replaced the wearing sprokets with stock, but noticing its top end isnt as nice. But its a little nicer in the dirt and tough hills. Just curious, if the consensus is to stick with the stock ratio or change em up? Also same ? for carbs. Are people sticking with the stock carb or upgrading? Thanks. Trying to get the most out of this machine. :D

    Also Is there anyone withing a few hours of Either Detroit Michigan, or Kitchener / or / Toronto Ontario thatas a good wrench on these? id like to get an overall refresh and see where it is, as Im not 100% how much the preivious owner(s) did with it. Figured if I can find a good wrench at a fair price, would be beneficial to us both, and I could learn a little maybe. :freaky