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

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

  1. Brendo404

    Brendo404 Adventurer

    Joined:
    Apr 13, 2018
    Oddometer:
    13
    Location:
    Tasmania, Australia
    Oh wow, thanks mate!
    I will post pics when I have it apart again, hopefully sooner than later.

    Yeah, I'm not keen on this hacked up airbox at all!
    It still has the std pipe on it, I'll be looking into changing it soon too.

    To the naked eye the float needle and seat looked fine, but I'll have a closer look when I get back in there next.

    Float seat o ring also seemed fine.
    But if it's available as a kit to replace them all, I'll probably just grab that and do them all anyway.

    I'll give the float and float hinges a better look too.

    It does run noticeably better now than it did before, not that it was super terrible before.
    But I do feel it could be better still.

    Another question I have is about kick starting them.
    I cannot for the life of me kick start it, cold or hot.
    And I've followed the guide on here about how to.


    Thanks.

  2. explodingmouse

    explodingmouse Been here awhile

    Joined:
    Jul 14, 2008
    Oddometer:
    522
    Location:
    Adelaide
    thats weird , the 03 that I used to have was the easiest bike to kickstart that I have ever owned , had a Honda xl250r years ago that was much harder.
  3. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    I'm well versed in starting my XR6, but it took a fair bit of practice to get the KTM to fire as easily. The basic technique is the same, but subtly different. The left-side kickstarter requires familiarisation too but I actually like it.
  4. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    I might have asked this previously but I can't find it anywhere, so I'll ask here.

    What diameter is the axle on the front & rear of a 2003 640 Adventure?
  5. enookway

    enookway Are we having fun yet?

    Joined:
    Jan 3, 2008
    Oddometer:
    752
    Location:
    Leeton NSW
    Did 03's have the 43mm forks? If so then 20mm axle.
    04 Adv went to 48mm forks (and twin disc) so 26mm axle
  6. rvt

    rvt Big Fat Trail Bikes

    Joined:
    Feb 20, 2011
    Oddometer:
    1,990
    Location:
    Western Australia
    This method was shown to me by two excellent fellows, Jack and Ross. Refined a bit to suit me. Be sure to wear suitable boots in case it kicks back. Hasn't happened to me, but I have heard the consequences can be nasty.

    1. Bike in neutral. Fuel tap on. Bike not on stand. Hold decomp in, give five or so full kicks.
    2. Release decomp.
    3. Key on, kill switch on, choke on if engine cold. MX boots on!
    4. Slowly operate the kick until you hear the auto decomp click.
    5. Apply just enough pressure to rotate slightly more. Just past tdc, where the pressure in the cylinder starts wanting to push the piston down. Not too far! If it goes too far, start again from step 4.
    6. One big, full stroke kick. Standing next to bike, using right foot, body facing slightly to rear of bike. I found grabbing the pannier frame and pulling the bike towards my foot helped a lot.

    This works well for me, even if the bike has sat for a couple of weeks.

    Good luck.
  7. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    Cold morning here, frosty. While the bike cranked over just fine, it wouldn't fire. It has been sitting for 4 cold weeks, and I've had the battery turned on to test lights, horn, etc. so maybe I took the edge off it.

    One kick though and it fired up, perfectly.:clap
  8. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    Got an answer in Thumpers thanks.
    It confirmed I have 20mm front and back (on a 2003 single-disc 48mm WP front end).
  9. braaap!

    braaap! Long timer Supporter

    Joined:
    Mar 16, 2005
    Oddometer:
    3,346
    Location:
    Here and There
    Hi Chaps!

    640Adv... Would anybody have some jetting data for running with a full titanium exhaust system, with Akro silencer (ha) running with no Db killer?
    TIA!
  10. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    6,171
    What is meant by "(ha)"? What year is the bike, how many miles are the on it and what condition is the airbox in?

    Regards,

    Derek
  11. braaap!

    braaap! Long timer Supporter

    Joined:
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    Hi Derek! 'ha' means... calling an Akrapovic a 'silencer' is a bit of a joke :)
    The motor is a 2006 model year, with 53336kms on the odometer. The airbox is standard, the snorkel opening has not been enlarged.

    I'm currently running the bike with a standard exhaust pipe system plus an akrapovic (ha) silencer (no Db insert), open sided (ktm) mesh airbox screen, snorkel in.
    BST40 has been refreshed with a kit, new slide (undrilled), slide guide, emulsion tube, jets and needle etc. My jetting data is recorded somewhere in my piles of notes.
    I'll have to dig that out to ascertain a base line...

    regards,
    Alfons
  12. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    6,171
    Hello Alfons,

    If the silencer is not silencing, it probably could use a repacking. The Akrapovič muffler has enough packing volume to where it should not have to be too loud, and my experience with them bears this out. Big singles are very, very hard on muffler packings, so it may just be time.

    Recommended settings for your setup:

    Float height: 15.7 mm
    Pilot jet: 45
    Needle clip position: 4th from top
    Main jet: 157.5
    Fuel screw: Start the engine, let it warm up and ride the bike around until it's hot. Using the idle speed screw, adjust the idle speed to 1450-1500 rpm. Set the CO to 3-3.5 %. If gas analysis is not available: coming from the lean side, adjust the fuel screw so that the strongest idle is achieved. You will notice there is a threshold where it becomes rich enough (enough turns out) to run strongest, beyond which no change is noticed. Adjust the idle mixture screw ~1/8-1/4 turn out from this threshold. Adjust the idle speed back to 1450-1500 rpm (as it is likely to have changed). Leave the mixture to the leaner side of these settings if the bike will be seeing altitudes much higher than the one it was set at. Set to the richer side if you would like the engine to idle well earlier during warm up. For diagnostic purposes, report back with the resultant setting.

    Regards,

    Derek
    GodSilla likes this.
  13. braaap!

    braaap! Long timer Supporter

    Joined:
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    Oddometer:
    3,346
    Location:
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    Derek, thankyou as always! you're responses and advice are so welcomed and respected.

    Yes, the big singles are hard on the muffler packing however... I recently rode my 950 (with single Akro) and my brother on the 640 on an 'adventure rider' school down here locally... Nobody winced.
    In fact, the school tutors / pupils made mention of how good both my V twin and the single sounded compared to the 'washing machine' noises the other standard bikes made :)

    Will report back as soon as my work affords me some quality shed time!
    Thanks again!!
  14. UncleGra

    UncleGra Road Grime

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    6,063
    Location:
    'neath the Southern Cross
    I re-pak my 625 with steel wool.
  15. motolab

    motolab Long timer

    Joined:
    Feb 16, 2006
    Oddometer:
    6,171
    Sir, you're welcome!

    Regards,

    Derek
  16. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    I just ordered a 320mm front disc from fleabay, $105, it has an orange centre so it must be alright. I woulda gone with torpedo7, but they are out of stock and double the price.
  17. dazza67

    dazza67 Been here awhile

    Joined:
    Apr 29, 2012
    Oddometer:
    631
    Location:
    Collinsville,Qld,Australia
    They make a huge difference in stopping power
  18. GodSilla

    GodSilla I did that.

    Joined:
    Sep 21, 2006
    Oddometer:
    11,535
    Location:
    GodSowncountry Australia
    Mine comes with 320mm standard eh, the 2003 was a single-disc model, 2004-onwards had twin 270mm discs. I am expecting a large increase in retardation from putting it onto a 17" front wheel though.:evil
  19. rowie

    rowie Been here awhile

    Joined:
    May 1, 2011
    Oddometer:
    340
    Location:
    Proserpine, QLD
    Details please :hmmmmm:D
  20. UncleGra

    UncleGra Road Grime

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    Oddometer:
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    Location:
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    Buy a packet of steel wool in a roll..pull the muffler apart and wrap the wool around the thingy...however much you reckon and seal it all back up with rivets and roof and gutter silicone sealer. Cheap easy and it works.