The KTM LC4 Reliability research thread

Discussion in 'Thumpers' started by demononthebrakes, May 25, 2006.

  1. demononthebrakes

    demononthebrakes Long timer

    Joined:
    Feb 7, 2006
    Oddometer:
    1,189
    Location:
    WNC
    Yes I found the longevity thread in the 640 LC4 thread link but I was hoping to get a little more specific.
    I would like to see the following information from LC4 owners (past or present).
    1. Bike:
    2. Year:
    3. Bought used or new:
    4. Current mileage:
    5. Modifications done:
    6. Mechanical work done:
    7. Upgrades done:
    8. Current tires on the bike:
    9. Percentage of road versus dirt use:
    10. Would you buy another one?:
    11. Did you replace the main shaft bearing (if applicable):
    12. Pic of the bike if available:


    Mine:
    1. 640 Dualsport
    2. 2001
    3. Used
    4. 4300
    5. Charcoal canister removal
    6. Swingarm bolt sheered off in the bottom insert nut. Couldnt get it extracted so I had to tear it all down and drill out the nut and bolt piece. Pressed in a 8mm metric nut and put it all back together with a new nut.
    7. Aluminum skidplate
    8. Pirelli Scorpion AT's
    9. 75% road (commute on it) 25% dirt
    10. I think so, ask me in another 10,000 miles
    11. No, still unsure if I will.
    12. See below
    Thanks for the input folks!
    #1
  2. creeper

    creeper Still alive...

    Joined:
    Dec 13, 2003
    Oddometer:
    10,718
    Location:
    Puget Sound
    OK n00bster... I'll bite.

    1. Bike: 640 Adventure
    2. Year: 2003
    3. Bought used or new: New
    4. Current mileage: 11 thousand something
    5. Modifications done: Here are a few.
    6. Mechanical work done: This, that and the other thing.

    Nearly everything I've done I've documented in DIY guides... so anyone who reads them would have a pretty good idea of what's gone tit's up and what it took to fix it.

    7. Upgrades done: The department of redundancy department... eh?
    8. Current tires on the bike: Dunlop D908RR
    9. Percentage of road versus dirt use: Overall since new, about 50/50 by miles, 30/60 by hours
    10. Would you buy another one?: Yep.
    11. Did you replace the main shaft bearing (if applicable): '03 not applicable
    12. Pic of the bike if available: Yep.

    C
    #2
  3. laramie LC4

    laramie LC4 crash test dummy!

    Joined:
    Sep 19, 2004
    Oddometer:
    2,578
    Location:
    Tucson, Az
    1. LC4-640
    2. 2002
    3. bought new
    4. 8,000+ (cables busted a few times, so i assume close 500 miles over odom.)
    5. all the usual mods, carb, airbox opened,
    6. full akra Titanium race exhaust, 18L and 9L tank set-ups
    7. mech work, dont even get me started, just replaced crank.....
    8. was runnning michelin Dez front/ Baja rear (now its got some cheap street tires on it till i get it licenced again)
    9. 90% dirt / 10% street (and ridden HARD!!!)
    10. would i buy another.... :dunno probably not at this point. i may be talked into the newer version when it comes out. of course once i have it fully running again, i could change my mind because up until it broke i would have sworen by these bikes.
    11. yes i replaced the main shaft bearing. also helped 2 other do theres and made a tool kit to send around to other members.
    12. pic of the bike, i dont know how long ktmtalk will let me post off their site but here it is...


    [​IMG]
    #3
  4. demononthebrakes

    demononthebrakes Long timer

    Joined:
    Feb 7, 2006
    Oddometer:
    1,189
    Location:
    WNC
    Creeper I am honored to have you as the second poster in this thread. Hopefully it will get many posts and merit graduation into the 640 threads compilation thread.
    Nice bikes there fellas!:wink: Laramie I still feel your engine work pain from KTMTalk.:cry
    Creeper is 8666 really that much difference?:lol3
    #4
  5. creeper

    creeper Still alive...

    Joined:
    Dec 13, 2003
    Oddometer:
    10,718
    Location:
    Puget Sound
    Maybe after you get 20 or 30 bikes, you can take all the raw data and crunch it into a single or multiple average figures and information, based on as yet to be determined factors.

    Lots of variables, use, country, typical terrain, owner serviced or dealer serviced (that might be a good one to add to the questions), frequency of riding, frequency of cleaning, rider skills on a 1-10 scale - one being less than a year total riding skill/experience (two different things really), 10 being a current or ex-amateur or better racer. Age of rider ah... shit, I could go on like this forever. :D

    I bet after you get enough data, you will be able to see several trends.

    This may actually turn into a valuable thread for potential buyers and maybe owners as well. Good idea. :thumb

    C
    #5
  6. myblubeemer

    myblubeemer MOA, IBA

    Joined:
    May 3, 2004
    Oddometer:
    593
    Location:
    Irving, Texas
    1. Bike: LC4 Enduro
    2. Year: 2000
    3. Bought used or new: Used with 600 miles
    4. Current mileage:3200
    5. Modifications done:Loaded risers and Scotts underbar stabalizer mount, Titanium exhaust, Renazo Seat (now has 41" seat height....I'm 6'6"), airbox mod, Fastway pegs, Touratech counter sproket cover, Pastrana bars
    6. Mechanical work done: Carb tuning, basic maintenance
    7. Upgrades done: Carbon fiber skid plate
    8. Current tires on the bike:Dunlop 606 (second set)
    9. Percentage of road versus dirt use:40 road 60 off road
    10. Would you buy another one?:Maybe..........I really like it and would consider the new model along with the Husky
    11. Did you replace the main shaft bearing (if applicable): Yes...........made my own tool from instrustions on web
    12. Pic of the bike if available:
    [​IMG]
    #6
  7. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    3,911
    Location:
    Rotoiti, North Is, New Zealand
    1. Bike: 640 Enduro
    2. Year: 2003
    3. Bought used or new: New
    4. Current mileage: 81 000 miles / 130 000 km
    5. Modifications done: SXC can, airbox side vent, drilled slide, rejet, 18L tank, handguards, chain guide, homemade headlight/dash mount, windscreen, rad guards, luggage rails, carrier rack.
    6. Mechanical work done: Servicing as per schedule (more or less), chains, sprockets, brake pads, wheel bearings, Countershaft seal x 2, resealed cam cover. Steering head bearings, suspension bearings, forks & shock have been serviced a few times.

    08 Update: 50 000km. Replaced worn out starter clutch, Preventive maintenance done - replaced cam follower rollers, cam bearings, waterpump seal, shaft & bearing, timing chain, head gasket, crank oil feed seal, all wheel bearings, had forks & shock serviced.

    09 Update: 80 000km. Repaired & strengthened cracked tool tube mount on subframe. Got forks serviced again. Rebuilt the carb with new slide & guide, needle & jet etc.

    10 Update: 95 000km. Major rebuild. Main worn out parts were conrod big end bearing, piston/rings, camshaft, water pump, valves. See thread: http://www.advrider.com/forums/showthread.php?t=633753

    14 Update: 130 000km. No major mechanical issues since rebuild, just normal maintenance plus serviced carb again a while back & fitted a new rear brake caliper.

    7. ...
    8. Current tires on the bike: Dunlop D605 front, Mitas E0-7 rear. Shown in pic is 'dirty' set, Pirelli MT21 front & Motoz Tractionator Desert HT rear
    9. Percentage of road versus dirt use: 80:20
    10. Would you buy another one?: Yep.
    11. Did you replace the main shaft bearing (if applicable): '03 not applicable
    12. Pic of the bike if available:

    [​IMG]

    Cheers
    Clint
    #7
  8. herobikes

    herobikes HE AINT HEAVY HES MY LC4

    Joined:
    Apr 28, 2005
    Oddometer:
    207
    Location:
    DOVER , NEW HAMPSTER
    My turn.

    1. Bike: lc4 640e SIXDAYS
    2. Year:2000
    3. Bought used or new: KTM OHIO demo 348 miles , used
    4. Current mileage:16,000
    5. Modifications done: Biggun full exhaust system , kehin fcr41mm carb ,jd jetting red needle , tourtech crossbar , hardparts side cover , twinair supermoto airfilter , oil temp gage, fastwaybardampeners , more.no charcoal can.
    6. Mechanical work done:Valves checked per maintenance schedule , oil and filters changed every 3000 miles , chain and sprockets at 14,600 miles.rear brake pads.
    7. Upgrades done:passmores centerstand tab , awesome and free. Genuine KTM spoke clips , front wheel rotor side only , Ralph Nader made them do it.Free.
    8. Current tires on the bike:metzler sahara
    9. Percentage of road versus dirt use:100% street now , was 90% street,10% dirt .10 .Would you buy another one? Yes , Next generation model.
    11. Did you replace the main shaft bearing (if applicable):no
    12. Pic of the bike
    #8
  9. markjenn

    markjenn Long timer

    Joined:
    Nov 9, 2003
    Oddometer:
    10,602
    Location:
    Bellingham, WA
    1. Bike: AdvR
    2. Year: 2000
    3. Bought used or new: Used
    4. Current mileage: ~17K
    5. Modifications done: Mainshaft bearing, dual rad fans, Boejangles seat, DirtBagz racks, jetting, SXC pipe, racing airbox sidecover, Protaper bars, headlamp switch, sidestand, accessory sockets, grips, Duke mirrors
    6. Mechanical work done: above + generally high maintenance
    7. Upgrades done: above
    8. Current tires on the bike: Scorpions
    9. Percentage of road versus dirt use: 75/25
    10. Would you buy another one?: Probably not, especially as lighter-weight twin adventure bikes come on strong
    11. Did you replace the main shaft bearing (if applicable): Yes
    12. Pic of the bike if available: not current

    [​IMG]
    #9
  10. KenR

    KenR Long timer

    Joined:
    Jun 28, 2004
    Oddometer:
    1,685
    Location:
    Jacksonville, OR
    1. 640 Adventure
    2. 2003
    3. Used
    4. 8900 miles
    5. Mods: Renazco seat, Stenhouse under-bar Scotts mount w/extra high risers, Scotts steering damper, ProTaper Pastrana FMX bars, orange paint, PRS suspension mods, TT roadbook, TT GPS mount, TT cockpit conversion (going on this week), tripmaster switch, heated grips, EXC front fender, PCCW fork guards, Stenhouse BST airbox screw, Hardparts airbox cover, Pro Circuit silencer (savin' for an Akra system!), enduro footpeg conversion, EE handguards, sidestand, sharkfin and aluminum lower chain guide (1 week out).
    6. General servicing, KTM front wheel recall, chassis teardown/reassembly of bearings/seals/questionable fasteners.
    7. See #5
    8. Dunlop 908RR Rally Raid, front/rear
    9. 75% dirt, 25% road
    10. Absolutely.
    11. N/A
    12. Pic of the bike if available:

    [​IMG]
    #10
  11. twisty sister

    twisty sister CRACK pot

    Joined:
    Nov 5, 2005
    Oddometer:
    2,059
    Location:
    "Asstracized"
    Hi!
    New KTM owner, lifelong rider here!
    I bought a lightly used ( a little over 1 k miles) VERY well taken care of
    2002 640 Adventure in April...
    LOVE IT!
    It already had the front wheel warranty /recall work done.
    Stock tires (Metzeler saharas) which I will likely replace with conti TKC 80's,
    Ride about 80% on, 20% off road at the moment, but planning more dirt!
    No mods beyond suspension (rebound/compression) adjustments
    ( I am a 5'9" female)
    Added a VERY NICE after market side stand ordered through twisted throttle, which allows me to keep the center stand on! ( A very kind "bike warming gift"!)
    QUESTION:
    >>>>>What is the deal with the mainshaft bearing????<<<<<<

    I love it so far...
    At this point, I WOULD buy it again....but it is new to me, so I am in the honeymoon phase!!!:rabia
    Sorry about the tiny,stock pic..my pics are too big to attach!
    #11
  12. gaspipe

    gaspipe Wandering Soul Super Moderator

    Joined:
    Jul 12, 2004
    Oddometer:
    11,354
    Location:
    Pickwick Lake, Tennessippi
    1. Bike: 640 Adventure
    2. Year: 2003
    3. Bought used or new: Used
    4. Current mileage: 4,000
    5. Modifications done: Akrapovic full exhaust, rejetted BST carb, modified airbox, Palo Verde resprung & revalved suspension, Emig 20mm offset triple clamps/damper/risers, EE handguards, 15T CS sprocket, Dirtbagz & Touratech rear AL plate.
    6. Mechanical work done: Rebuilt motor, twice :bluduh
    7. Upgrades done: Woody's Superlaced Sun rims (1.85F, 2.50R) & HD stainless spokes
    8. Current tires on the bike: Dunlop 606 front, MT21 Pirelli rear
    9. Percentage of road versus dirt use: 10% road, 90% dirt :patch
    10. Would you buy another one?: Keeping this one :nod
    11. Did you replace the main shaft bearing (if applicable): N/A
    12. Pic of the bike if available:

    [​IMG]
    #12
  13. dirtrider

    dirtrider Dusty Adventurer

    Joined:
    Nov 12, 2003
    Oddometer:
    3,340
    Location:
    Kalispell, Montana
    1. Bike:LC4 640 Enduro
    2. Year:2001
    3. Bought used or new:Bought in 01 with 900 miles from my KTM rep but I had put over 500 miles on it while he had it.:evil
    4. Current mileage: 16000 + speedo cable broke a few times
    5. Modifications done: Acerbis hand guards, Pro Taper Pastrana Bars, KTM bar risers, LED turn signals and taillight, supermoto rear fender extension, "comfort seat", Pro Moto Billet rear rack, snorkel removed, KTM air box screen, Loaded fuel screw, Adventure skid plate, Braking wave rear rotor, 15 tooth counter shaft sprocket, SXC silencer, straight through crossover pipe, thinner base gasket, forged piston, and probably more I can't remember.
    6. Mechanical work done: Replaced counter shaft bearing at around 5000 miles-don't wait. Waiting for it to fail is expensive! Just rebuilt engine over the winter as the lower end of the rod failed at 15000 miles
    7. Upgrades done: Adventure Rider "Ride the World" sticker :lol3
    8. Current tires on the bike: Dunlop 908RR's, but will go back to MT21's
    9. Percentage of road versus dirt use: Road 10% Dirt 90%
    10. Would you buy another one?:Absolutely
    11. Did you replace the main shaft bearing (if applicable):YES
    12. Pic of the bike if available:

    [​IMG]
    #13
  14. potatoho

    potatoho Cheese and Rice!

    Joined:
    Aug 3, 2004
    Oddometer:
    4,709
    Location:
    Sea-level
    1. KTM 640 LC4
    2. 1999
    3. Used w/ 3500 miles
    4. 15,300 miles
    5. Modifications done: HSR42 carb, IDS2 silencer, Emig stabilizer, Tornado G1 camshaft.
    6. Mechanical work done: Wheel bearings, cam bearings, clutch, sprockets, speedo cable.
    7. Upgrades done: 18L tank, Rallye foot pegs, airbox.
    8. Current tires on the bike: Michelin Desert front, Teraflex rear
    9. Percentage of road versus dirt use: 70/30
    10. Would you buy another one?: Yes
    11. Did you replace the main shaft bearing (if applicable): Yes, immediately
    12. Pic of the bike if available:

    [​IMG]
    #14
  15. gaspipe

    gaspipe Wandering Soul Super Moderator

    Joined:
    Jul 12, 2004
    Oddometer:
    11,354
    Location:
    Pickwick Lake, Tennessippi
    1. Bike: 620RXC
    2. Year: 1996
    3. Bought used or new: New
    4. Current mileage: ???
    5. Modifications done: Uptite exhaust, 41mm FCR, modified airbox, revalved & resprung suspension, Corbin seat, '95 Acerbis desert tank, 26mm billet bar risers, Protapers, Magura Jack hydraulic clutch, EE handguards, Devol radiator guards
    6. Mechanical work done: headstock, wheel & sprocket carrier bearings, clutch pack, cam bearings
    7. Upgrades done: see #5
    8. Current tires on the bike: Pirelli MT21 F&R
    9. Percentage of road versus dirt use: 5% road, 95% dirt
    10. Would you buy another one?: YES (if they still made it) :thumb
    11. Did you replace the main shaft bearing (if applicable): YES
    12. Pic of the bike if available:

    [​IMG]
    #15
  16. ChrisC

    ChrisC Amal sex?

    Joined:
    Feb 25, 2003
    Oddometer:
    6,317
    Location:
    Prescott, Arizona USA Earth
    1. Bike: 640 Adventure
    2. Year: 2003
    3. Bought used or new: new
    4. Current mileage: 6,250
    5. Modifications done: IDS2 pipe, side cover, Takagaso replacement front wheel (thank you, NHTSA), RXC chainguide, Dual Star mirrors and headlamp protectors, push button fork bleeders...... etc.
    6. Mechanical work done: routine maintenance, fork seals under warranty
    7. Upgrades done: Garmin 76S/Touratech mount, SW-Motech kickstand, Dirt-Bagz, KTM tank bag, Jimmy Renazco Racing Saddle (the collectible, pre-Creeper type :lol3 ), Stealth rear sprocket, Takagaso X-ring chain.
    8. Current tires on the bike: Dunlop D606
    9. Percentage of road versus dirt use: 60/40
    10. Would you buy another one?: in a minute...
    11. Did you replace the main shaft bearing (if applicable): n/a
    12. Pic of the bike if available:

    [​IMG]
    #16
  17. bikemoto

    bikemoto Tyre critic

    Joined:
    Oct 24, 2004
    Oddometer:
    2,824
    Location:
    Nelson, New Zealand
    1. Bike: 640 LC4 Adventure
    2. Year: 2005
    3. Bought used or new: New April '05
    4. Current mileage: 39,500km
    5. Modifications done: Dual-Star grip heaters, RHS disc- & caliper-ectomy. High front guard from '03 EXC. Part-time 12L tank + shrouds + seat from LC4 Enduro. Removed SAS & EPC. Uncorked: exhaust/carb/airbox mods. 4.8N/mm fork springs. 28mm bar risers.
    6. Mechanical work done: Routine servicing plus Cam Cover sealant leak fixed @ 15,000km, Rocker Arm Roller bearings replaced @ 20,000km. Wheel/steering/suspension bearings replaced as needed. Starter clutch worn out (not helped by missing starter gear needle bearing on crank!!). Base gasket replaced @ 37,000km, valve stem seals replaced & valves lapped in.
    7. Upgrades done: ProGrip 797 grips, Low-with-High headlight relay, headlight bulbs "Plus 50" xenon-halogen mix, retrofit chain guide and retaining plate, Rallye sprocket cover. Rim locks. SW-MOTECH Side Stand.
    8. Current tires on the bike: Metzeler MCE Six Days Extreme (F) Michelin Cross AC10 (R). Or Metzeler MC4. Or Pirelli MidSoft32 (F) MX eXTra (R). Take your pick - I do. :D
    9. Percentage of road versus dirt use: 20:80.
    10. Would you buy another one?: LC4 Enduro/SXC, yes; LC4 Adventure, maybe.
    11. Did you replace the main shaft bearing (if applicable): n/a
    12. Pic of the bike if available:
    [​IMG]
    [​IMG]
    [​IMG]
    #17
  18. demononthebrakes

    demononthebrakes Long timer

    Joined:
    Feb 7, 2006
    Oddometer:
    1,189
    Location:
    WNC
    "genuine KTM spoke clips" Why does that make me laugh!:lol3 I am waiting on that "mod" to be done at my dealer when they get the dang things in.:deal
    #18
  19. JonL

    JonL Enduro NEEC

    Joined:
    Nov 30, 2005
    Oddometer:
    67
    Location:
    United Kingdom of England
    1. Bike: 640 LC4 Enduro
    2. Year: 2001
    3. Bought used or new: Used
    4. Current mileage: ? No dedicated speedo
    5. Modifications done: Altered wiring to power GPS/Touratech trip and roadbook
    6. Mechanical work done: routine maintenance BY THE BOOK !
    7. Upgrades done: Airbox mod
    8. Current tires on the bike: Dunlop D907F/D908R
    9. Percentage of road versus dirt use: 99% in the technical dirt
    10. Would you buy another one?: Don't need to I don't intend selling this one
    11. Did you replace the main shaft bearing: If it ain't broke don't fix it
    12. Pic of the bike if available: Yeah............ somewhere, maybe later :1drink
    #19
  20. Happe

    Happe Offroad Nut

    Joined:
    Sep 25, 2003
    Oddometer:
    685
    Location:
    Herts UK
    1. Bike: '98 Lc4 660 Rally
    2. Year: 1998
    3. Bought used or new: Used from Dakar contestant
    4. Current mileage: 16000m
    5. Modifications done: Mikuni TM42-6, Fan for radiator, neoprene Sox for forks, LED rear light, Oil thermometer
    6. Mechanical work done: Main shaft bearing, cam shaft bearing, valve shafts, piston rings, barrel re-chromed.
    7. Upgrades done: The Rally has all upgrades :wink:
    8. Current tires on the bike: Pirelli MT21 for road use, Desert for the desert
    9. Percentage of road versus dirt use:50/50
    10. Would you buy another one?: I have another one.
    11. Did you replace the main shaft bearing (if applicable): yes on both, why not? Costs peanuts and let you sleep better, same for the newer type camshaft bearings.
    12. Pic of the bike if available:[​IMG]

    More here
    #20