The KTM LC4 Reliability research thread

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

  1. tHEtREV

    tHEtREV Encouragement award recipient. tEAM iDIOT.

    Joined:
    Apr 14, 2007
    Oddometer:
    12,297
    Location:
    Middle Park, Brisbane, Australia
    1. Bike: 640 ADV
    2. Year:02
    3. Bought used or new: used in 08?
    4. Current mileage: 56000 Klm
    5. Modifications done: 9l rear tank, 92 600exc seat and rear plastics, subframe support (also holds rear tank). I think thats all.
    6. Mechanical work done: None that I know of.
    7. Upgrades done:nil
    8. Current tires on the bike:Think I'm trying a Trail wing on the rear, and a Pirelli scorpion on the front.
    9. Percentage of road versus dirt use:50/50, it's main use now is out back touring.
    10. Would you buy another one?: I did.
    11. Did you replace the main shaft bearing (if applicable): not yet, but I will if I do the planed rebuild (just for preventative purposes, it's not on it's last legs, I hope).
    12. Pic of the bike if available:

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    my old 92 600..
    [​IMG]
  2. hg102

    hg102 Been here awhile

    Joined:
    Sep 18, 2006
    Oddometer:
    163
    Location:
    Pacific Northwest
    1. Bike: 640 Adventure
    2. Year: 2002
    3. Bought used or new: used 10,500
    4. Current mileage: 14,000
    5. Modifications done: EXC exhaust, 39mm keihin, led running lights, rewired all lighting circuits w relays and heavier wire, soft lugage w racks
    6. Mechanical work done: yes
    7. Upgrades, Rich's custom seat,foot pegs, carbon fiber tank gards and garmin 276c.
    8. Current tires on the bike: dunlop 606s
    9. Percentage of road versus dirt use: 65 road, 35 dirt
    11. Did you replace the main shaft bearing (if applicable): yes, failed at 12,500 but shut down before other damage incured
    12. Pic of the bike if available:

    I also have a 99 640Adventure. I really enjoy riding and working on these excellent bikes. Best of all they don't have computers to create problems.
  3. izom

    izom Been here awhile

    Joined:
    Jun 9, 2006
    Oddometer:
    429
    Location:
    LandofArnoldS/Vienna
    ...i have now 20tkms on the clock!-

    should i open the head and check the valves or not??

    or do you think it makes another 10tkms??:evil

    and PLEASE can the new 640 adv.riders update this tread with their statistics!?(i know there are many new here!)

    greetz peter
  4. erdsh

    erdsh KTM 640 Adventure

    Joined:
    Mar 14, 2008
    Oddometer:
    106
    Location:
    GY
    1. Bike: 640 Adventure
    2. Year: 2001
    3. Bought used or new: Used
    4. Current mileage: about 70,000 km
    5. Modifications done: build the roadbook holder/ GPS mount, LEDs replaced the original lights.
    6. Mechanical work done: Leaky countershaft seal, welded broken rear subframe. Electric wires renew. Electric connectors replaced. balancer shft bearings replaced. the Clutch bearing replaced. Clutch at arount 50,000. Carb rebuild. Cables replaced. A lot of electric work done. Rebiuld Fuel Pump. oil leaks are all over.
    7. Upgrades done: Lowered. (this is downgrade)
    8. Current tires on the bike: Running the Karoo everyday. use the Kenda carlsbad for long travels and desert races.
    9. Percentage of road versus dirt use: 30/70. Nothing too technical. Mostly desert or rocky trails with a little singles.Use it as everyday commuter.
    10. Would you buy another one?: It's amazing, no doubt, but I would like a smaller bike like the 300 or the new 350 4 strok for technical riding.
    11. Did you replace the main shaft bearing (if applicable): not yet.
    12. Pic of the bike if available:

    Attached Files:

  5. erdsh

    erdsh KTM 640 Adventure

    Joined:
    Mar 14, 2008
    Oddometer:
    106
    Location:
    GY
    another pic of the bike

    Attached Files:

  6. Happe

    Happe Adventure Bike Spanner Man

    Joined:
    Sep 25, 2003
    Oddometer:
    694
    Location:
    Wales UK
    1. Bike: 640 Adventure
    2. Year:1998
    3. Bought used or new: used 101048Km
    4. Current mileage: 101600
    5. Modifications done: DAM exhaust, 39mm keihin, led tail light, CEV Switches, Handlebar risers
    6. Mechanical work done: yes, 95000Km Piston cracked, known issue with the cast pistons, 101048Km Crank Bearing seized. New 2004 Engine with hydraulic Clutch fitted. Was lying around in the Garage :evil
    Adventure Story
    7. Upgrades, Rally Seat, carbon fiber tank gards and garmin zumo 660, Paintjob
    8. Current tires on the bike: Karoos
    9. Percentage of road versus dirt use: 80 road, 20 dirt
    10. Would you buy another one?: I have three, isn't that enough?
    11. Did you replace the main shaft bearing (if applicable): No in old engine, new one has the uprated one
    12. Pic of the bike if available:
    [​IMG]

    cu
    Stefan
  7. Happe

    Happe Adventure Bike Spanner Man

    Joined:
    Sep 25, 2003
    Oddometer:
    694
    Location:
    Wales UK
    1. Bike: 660 Rally
    2. Year:1998
    3. Bought used or new: used 18000Km (including 1x Dakar in 1999)
    4. Current mileage: 40000
    5. Modifications done: 2004SMC high Flow Head and cylinder & Ingnition fitted, 41mm keihin, led tail light, Stenhouse Racing SteeringDamper mount with Handlebar risers, Scotts Steering Damper, Selfmade wiring
    6. Mechanical work done: yes, 39000Km Piston tired, shim of Rocker schaft failed and rocker seized, New Piston and Valve drive fitted. Rally Overhaull
    7. Upgrades, It is a Rally Bike therefore perfect :rofl
    8. Current tires on the bike: Karoos
    9. Percentage of road versus dirt use: 50 road, 50 dirt
    10. Would you buy another one?: I have three, isn't that enough?
    11. Did you replace the main shaft bearing (if applicable): Yes, first job done just in case
    12. Pic of the bike if available:
    [​IMG]

    cu
    Stefan
  8. pcvance

    pcvance Walk Verplank

    Joined:
    Jul 13, 2010
    Oddometer:
    5,993
    Location:
    Sequoia Country
    1. 640-E
    2. 2000' the last year with WP 50MM extreem forks
    3. bought used w/11000 miles
    4. current mileage 19725 miles
    5. bst-40 mods/KTM air box side cover and KTM exhaust/bars & risers/rear rack
    6. only routine matinance so far...
    7. skid plate, Cycra handguards, Wolfman tankbag and side stand
    8. D606 front and rear
    9. 40 slab/60 dirt
    10. yep! great bikes
    11. nope... not yet
    12. here it is...

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  9. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    4,852
    Location:
    Rotoiti, North Is, New Zealand
    Indeed. :clap I just updated my original post & added a link to my 95K km rebuild thread.

    Peter: both my sets of cam bearings have lasted over 45K km, but many have had theirs fail at less. I'm planning to replace the current set when they have done 40K km.

    Cheers
    Clint
  10. Elefant 900 Rad

    Elefant 900 Rad Hedley

    Joined:
    Dec 9, 2003
    Oddometer:
    1,195
    Location:
    SoCal
    1. Bike: 640 LC4 Dualsport
    2. Year: 2000
    3. Bought used or new: New
    4. Current mileage: 10,000+...not sure, speedo-odo broke long time ago (I ride my 950 a lot more).
    5. Modifications done: Not much, just accessories.
    6. Mechanical work done: Crank Bearing (my fault, air filter did not seat properly, allowed dirt into engine), other...typical maintenance.
    7. Upgrades done: Modified seat, rear tail rack, modified rear turn signals, Trailtech Computer.
    8. Current tires on the bike: Dunlop D606 front & rear
    9. Percentage of road versus dirt use: 10% road, 90% dirt, lots of single track (this is my small bike).
    10. Would you buy another one?: Yes due to reliability and great motor.
    11. Did you replace the main shaft bearing (if applicable): NA for 2000 ?
    12. Pic of the bike if available: will post later.

    Wooops.....
    [​IMG]

    [​IMG]
  11. Happe

    Happe Adventure Bike Spanner Man

    Joined:
    Sep 25, 2003
    Oddometer:
    694
    Location:
    Wales UK
    The models after 2003 have the uprated Mainshaftbearing.
    Your 2000 Model still has the normal Ball Bearing. What is sort of a legacy from the older Lc4 Sports Days. The times when the engines got a revision every few races.
    The swap is fairly easy.
    I wouldn't do it now but next time you plan a large service and maybe some work on the clutch.

    cu
    Stefan
  12. willembron

    willembron n00b

    Joined:
    Jan 5, 2008
    Oddometer:
    8
    Location:
    Burkina Faso - West Africa
    1. Bike: KTM 640 Adventure
    2. Year: 2005
    3. Bought used or new: new
    4. Current mileage: 29650 km
    5. Modifications done: Akrapovic, Woody's rims, lightning wires for better lights, tank protection, ...
    6. Mechanical work done: many, water pump, rockers bearings, chain
    7. Upgrades done: ...
    8. Current tires on the bike: MCE Karoo
    9. Percentage of road versus dirt use: 50% 50% I would say
    10. Would you buy another one?: yes with 6 gear!
    11. Did you replace the main shaft bearing (if applicable): nope
    12. Pic of the bike if available:

    [​IMG]
  13. thisisjess

    thisisjess Adventurer

    Joined:
    Jul 24, 2011
    Oddometer:
    41
    Location:
    Atlanta, Ga.
    1. Bike: KTM 640 LC4 Enduro
    2. Year: 2000
    3. Bought used or new: used 3/2012
    4. Current mileage: 10,500 mi when purchased now 19,218 miles
    5. Modifications done: easily adjustable mixture screw, USB port on bars, X2 headlight
    6. Mechanical work done: nothing but oil changes, fork seals, leaky rocker cover...
    7. Upgrades done: ...
    8. Current tires on the bike: Shinko 705 then back to Michelin T63's
    9. Percentage of road versus dirt use: 75% 25%
    10. Would you buy another one?: I am in love. but on cross country trips an extra gear would help.
    11. Did you replace the main shaft bearing (if applicable): nope
    12. Pic of the bike if available:
    [​IMG]
    [​IMG]
  14. timolgra1

    timolgra1 Been here awhile

    Joined:
    Mar 8, 2009
    Oddometer:
    639
    Location:
    No fixed abode
    1. Bike: 640ADV

    2. Year: 2006

    3. Bought used or new: used

    4. Current mileage: 14,000

    5. Modifications done: see upgrades

    6. Mechanical work done: Fork seals, preventative maintenance: cam followers, water pump, suspension linkage, swing arm bearings, wheel bearings,

    7. Upgrades done: fcr 41 carb, open air box, Akro, Renazco, bar risers, Ohlins steering damper, stiffer fork springs, high mudguard, crash bars, pannier frames, f650 screen extension, Exel front rim, HID lights, heated grips, QR fuel lines, Roadbook, hand guards......probably more:D

    8. Current tires on the bike: F Michelin Desert R Dunlop D908

    9. Percentage of road versus dirt use: 80% dirt

    10. Would you buy another one?: If only!!

    11. Did you replace the main shaft bearing (if applicable): N/A

    12. Pic of the bike if available:

    [​IMG]

    [​IMG]

    [​IMG]
  15. dolphins13

    dolphins13 orange rules

    Joined:
    Jan 7, 2012
    Oddometer:
    270
    Location:
    spo wa
    1. Bike: 640e

    2. Year: 1999

    3. Bought used or new: used

    4. Current mileage: 11,500 (bought with 9,500m)

    5. Modifications done: bigger main jet and opened stock exhaust. snorkle was already removed

    6. Mechanical work done: Replaced clutch cable, sprockets once and chain twice

    7. Upgrades done: none

    8. Current tires on the bike: kenda 270 gonna try t63's
    9. Percentage of road versus dirt use: 50/50

    10. Would you buy another one: If I lost this one some how?

    11. Did you replace the main shaft bearing (if applicable): no

    12. Pic of the bike if available:

    Best overall bike I have ridden by far.
  16. sir phily

    sir phily Been here awhile

    Joined:
    Aug 31, 2008
    Oddometer:
    410
    Location:
    Bendemeer NSW
    1. Bike: 640 Adventure
    2. Year: 07
    3. Bought used or new: New
    4. Current mileage: 40,000
    5. Modifications done: High guard,1 front disc,steering damper,carby rejet, full set racks,ktm performance pipe, higher front screen, gps, uhf, starcom 1 intercom, led spots, tank guards.
    6. Mechanical work done: Nothing major
    7. Upgrades done: Many
    8. Current tires on the bike: Super explorer rear M21 front
    9. Percentage of road versus dirt use: 60 dirt 40 sealed
    10. Would you buy another one?: Sure would
    11. Did you replace the main shaft bearing (if applicable): N/A[​IMG][/URL][/IMG]
    12. Pic of the bike if available:
    Mine touring the top of WA in Australia
  17. Tonicu

    Tonicu Been here awhile

    Joined:
    Dec 9, 2011
    Oddometer:
    186
    Location:
    Spain
    1. Bike: 640 Enduro
    2. Year: 03
    3. Bought used or new: used
    4. Current mileage: 52k kms
    5. Modifications done: n/a
    6. Mechanical work done: inlet ( and all other ) bearing under the rocker cover, as the inlet seized at 38K kms. Waterpump shaft and seal for peace of mind, carb needle and slide and a rebuilt shock.
    7. Upgrades done: Not many, only those as per LC4 advrider great thread.
    8. Current tires on the bike: Mitas E 10
    9. Percentage of road versus dirt use: 20 road / 80 dirt
    10. Would you buy another one?: Oh yes.
    11. Did you replace the main shaft bearing (if applicable): n/a
    12. Pic of the bike if available:


    [​IMG]
  18. Happe

    Happe Adventure Bike Spanner Man

    Joined:
    Sep 25, 2003
    Oddometer:
    694
    Location:
    Wales UK
    1. Bike: KTM Lc4 Adventure
    2. Year: 1998
    3. Bought used or new:Used
    4. Current mileage:63500miles or 102000Km
    5. Modifications done:paintjob and Husaberg front fender
    6. Mechanical work done:New HiFlow Engine at 101000Km
    7. Upgrades done: DAM Exhaust, Paintjob, HD rear Spring, HD Fork Springs
    8. Current tires on the bike:Karoo, best on road tires I know :wink: (not the (T) ones)
    9. Percentage of road versus dirt use:The milage mainly done in South America, so 70/30 Off to Onroad
    10. Would you buy another one?:it is my fourth Lc4, what else is there?
    11. Did you replace the main shaft bearing (if applicable):It was replaced on the old engine. The HiFlow has the newer bearing from the factory
    12. Pic of the bike if available:
    [​IMG]

    *5 - The original engine had a big end bearing gone after 101000Km.
    The original cast piston failed at 96000Km and was replaced by the stronger forged pistons of the models after MY2000
  19. drmax

    drmax Been here awhile

    Joined:
    Sep 3, 2005
    Oddometer:
    343
    Location:
    Martinsville, IN
    1. Bike: KTM Lc4 USA model
    2. Year: 2002
    3. Bought used or new: New
    4. Current mileage:53000miles
    5. Modifications done:replaced all red plastic to orange, with tank decal
    6. Mechanical work done:Just spockets, chain and tires
    7. Upgrades done: None
    8. Current tires on the bike:Battle Axe. They go about 8K
    9. Percentage of road versus dirt use:100% street.
    10. Would you buy another one?:If this one quit. Plan on rebuilding.
    11. Did you replace the main shaft bearing (if applicable):Yes, around '04. It ate that p.o.s. bearing. I flushed out the system, installed new.
    12. Pic of the bike if available:
  20. docwyte

    docwyte Long timer

    Joined:
    Dec 23, 2012
    Oddometer:
    2,577
    Location:
    Denver, CO
    1. Bike: KTM LC4 Adventure USA model
    2. Year: 2006
    3. Bought used or new: Used
    4. Current mileage:8100miles
    5. Modifications done:Leo Vince exhaust, KTM rally book holder/GPS mount, Touratech rear tail rack, side pannier racks, Scotts Steering dampener/Stenhouse Racing mount, 2" Rox Risers, Highway Dirt Bikes hand guards, LED auxiliary lights, Touratech hard cases and Gobi hard cases.
    6. Mechanical work done:Front TKC80, oil change
    7. Upgrades done: None
    8. Current tires on the bike:Front TKC80, Rear Heidi K60
    9. Percentage of road versus dirt use:70/30 street/dirt
    10. Would you buy another one?: More than likely, unless KTM finally makes a 690 Adventure.
    11. Did you replace the main shaft bearing (if applicable): Nope
    12. Pic of the bike if available:

    [​IMG]