Oz/Kiwi KTM 640 ADV riders sign in here please.

Discussion in 'Australia' started by overlandr, May 10, 2006.

  1. horizonchasser

    horizonchasser Adventurer

    Joined:
    Jul 15, 2011
    Oddometer:
    69
    Location:
    Hunter valley nsw
    After trying the filter skins,oiled up chucks,and still dusting mine , I replaced the air box with a lc4 supercomp airbox.which gave me a exc size air filter ,problem solved.I put a flat slide carby on as well .dynoed works great.
    enookway and GodSilla like this.
  2. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    10,570
    Location:
    GodSowncountry Australia
    Any particular model? Is it a straight bolt-in fit?

    :lurk
  3. enookway

    enookway Are we having fun yet?

    Joined:
    Jan 3, 2008
    Oddometer:
    649
    Location:
    Leeton NSW
    Online parts fische shows 1994-96 620 and 400SC airboxs as PN 58306001500 which is also used in all the 640 supermotos and SMCs up to 2006.
    These have a big round filter. Wonder why they ran a smaller filter in the “dirt” bikes?

    So are the bike wreckers going to get a run on LC4 filter boxs next week:D
  4. horizonchasser

    horizonchasser Adventurer

    Joined:
    Jul 15, 2011
    Oddometer:
    69
    Location:
    Hunter valley nsw
    Not sure on model I got mine from a 400 super comp as same same ,had to cut off and shift a couple off mount tabs. The story I got was when they moved to electric start they put the battery in the air box and put a 65 cc air filter ,apparently the part number is the same on both bikes...
  5. Aussie Steve

    Aussie Steve Long timer

    Joined:
    Apr 9, 2007
    Oddometer:
    1,475
    Location:
    Maitland
    I used a 5830600100 to do mine. Also stuck an sxc dzus in the seat and so can now do air filter swaps with no tools.
  6. LivingdeadCamo

    LivingdeadCamo Long timer

    Joined:
    Feb 6, 2016
    Oddometer:
    1,034
    Location:
    Woongarrah, NSW, Australia.
    I've got a 2005 625sxc, sight glass on the stator cover is cracked and weeping small amounts of oil.

    Any suggestions on a decent easy fix?
  7. enookway

    enookway Are we having fun yet?

    Joined:
    Jan 3, 2008
    Oddometer:
    649
    Location:
    Leeton NSW
    Do you run the airbox lid or open at the top?

    My 06 does the same although its not cracked. I removed it, cleaned and refit with the specified loctite (648) and it still leaks. May be leaking between glass and seal.
    LivingdeadCamo likes this.
  8. Aussie Steve

    Aussie Steve Long timer

    Joined:
    Apr 9, 2007
    Oddometer:
    1,475
    Location:
    Maitland
    Last time I had issues removed with a seal pick and resealed new one with toyota black sealant which I'm pretty sure is just three bond rtv.
    LivingdeadCamo likes this.
  9. Aussie Steve

    Aussie Steve Long timer

    Joined:
    Apr 9, 2007
    Oddometer:
    1,475
    Location:
    Maitland
    Running the 620/400 airbox with large air filter which is also early rallye one and I'm pretty sure never had a lid
  10. enookway

    enookway Are we having fun yet?

    Joined:
    Jan 3, 2008
    Oddometer:
    649
    Location:
    Leeton NSW
  11. horizonchasser

    horizonchasser Adventurer

    Joined:
    Jul 15, 2011
    Oddometer:
    69
    Location:
    Hunter valley nsw
    Yes but made up a aluminium battery holder and attached the relay to it . Used a ttr 250 battery for years, moved on to a shoria lthium a few years ago of the equivalent size. was always gunna do the duz fastener in the top of the seat,or 950 SE little lever cable release style .
  12. UncleGra

    UncleGra Road Grime

    Joined:
    Jan 16, 2008
    Oddometer:
    5,505
    Location:
    'neath the Southern Cross
    Mine started to leak at about 50K.I cleaned it and put a dab of Neadit, or whatever that stuff is called...fixt. Replaced the seal eventually when I had to replace the stator after the teeth from the starter motor cog wheel went thru it and took chunks out of it because the sprag clutch was stuffed and would jam and that caused the starter cog wheel to take the hit. DSCN0388 (Large).JPG DSCN0390 (Large).JPG DSCN0391 (Large).JPG DSCN0469 (Large).JPG
    LivingdeadCamo likes this.
  13. UncleGra

    UncleGra Road Grime

    Joined:
    Jan 16, 2008
    Oddometer:
    5,505
    Location:
    'neath the Southern Cross
    a bit of the cog punched a hole in the fly wheel too..the hole is still there at 95 K DSCN0475 (Large).JPG
  14. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    10,570
    Location:
    GodSowncountry Australia
    That's a great demonstration of why a dodgy sprag clutch should be fixed. Thanks Unc.
  15. Dee Cee

    Dee Cee Been here awhile

    Joined:
    Mar 6, 2006
    Oddometer:
    489
    Location:
    Newlyn. Victoria.
    New one every 40 to 50k, on my third one and the stator looks like new and the bike starts beautifully.
  16. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    5,709
    Keep in mind that the LC4 engine is not overly tolerant to significant improvements in cylinder filling, i.e. it has a tendency toward detonation problems (unless adequate countermeasures are undertaken). The absolute minimum conditions under which I would install a flat slide carburetor would be: high flow model with snorkel and stock airbox lid in place, igniter box from an originally FCR-equipped single pipe model installed, exhaust breathing improved via Akrapovič or Leo Vince slip-on without quiet insert, and jetted correctly.

    Regards,

    Derek
  17. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    5,709
    You are asking for detonation issues unless other significant measures were undertaken to prevent it.

    Regards,

    Derek
  18. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    5,709
    It is accelerated by poor vent filtration, race lid installation, snorkel removal, airbox cutting/drilling, slide drilling, riding in dusty conditions, and use at lower rpm with varying throttle positions. Even if all of there conditions were absent, it would be very unusual to get to 30K km before the slide guide was worn beyond 0.25 mm (i.e. the depressions in the bottom corners adjacent to where the slide bottoms are fewer than 0.25mm deep).
    This can be due to the ring end gaps being too large and/or lined up. What is the leakdown percentage?

    Regards,

    Derek
  19. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    4,480
    Location:
    Rotoiti, North Is, New Zealand
    I've replaced a couple. I think you only have a few starts between it starting to slip & trashing the pawls, if you get it quick a new spring might sort it. I reckon a new spring as cheap preventive maintenance every 40K km is probably the ticket, did that last time & the old spring was indeed starting to look tired.

    Good tips thanks! I've never had cause to check the leakdown. I did check the end gaps on the new rings when she got rebuilt & they were all good, at the low end of the spec IIRC. The gaps were definitely offset as per the manual on assembly.

    Cheers
    Clint
  20. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    10,570
    Location:
    GodSowncountry Australia
    Replacing the spring in the sprag clutch periodically will see many trouble-free years of using the electric foot.

    Mine started to go consistently bad at around 50k, and after a period of getting to know and love the kickstarter I replaced the spring at 52k, it wouldn't grab and turn the motor over any more. Now it fires up first prod every time.