What's the difference:2002,3,4 Ktm640 adv

Discussion in 'Thumpers' started by FlyinGo!!!!!, Apr 29, 2005.

  1. FlyinGo!!!!!

    FlyinGo!!!!! Ride it like a two stroke

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    Can anyone tell me the differences between the 2002-3-4 years of the KTM 640 Adventure?
    #1
  2. Velocibiker

    Velocibiker Adventure Antagonist

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    2-3

    hiflo head
    hydro clutch
    assist tab added to center stand
    different valves/cam? (not sure)
    different seat
    power outlet in dash

    what else?

    3-4

    Not sure as '04 was not available in the US


    3-5

    front end suspension & brakes same as those on the 950.

    what else?
    #2
  3. Mack

    Mack Gone, but never forgotten. RIP, Mack...

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    http://www.ADVRider.com/forums/showthread.php?t=76968
    #3
  4. creeper

    creeper Still alive...

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    2003 As stated by Velo and... to my knowledge:

    cam (timing change unknown)
    valves (32mm vs. 30mm exhaust valves... not retrofitable. Must retro entire "high-flow" head)
    ignition map (again, change unknown)
    exhust system diameter, location of merge collector and elimination of separate cross-over.
    oil pump drive ratios incresed
    location of fuses moved to battery tray area.
    structural change in swingarm "arms" and chain adjuster blocks.

    That's all I got off the top of my head,
    Creep
    #4
  5. Loadedagain

    Loadedagain making chips

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    2002 is the best. :wink:
    #5
  6. gaspipe

    gaspipe Wandering Soul

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    Couple other things not yet mentioned in the +'03 bikes:

    1) different dashboard panel, IMO and tach
    2) different tranny gearing (I think the primary ratio was different)
    3) slightly different fuel plumbing
    4) 40BST carby fitted with a TPS (to tell that revised CDI box what to do)
    5) oil sightglass replaced dipstick in new sidecover castings
    6) revised mainshaft bearing

    Can't think of anything else off the top of my head. Work sux.
    #6
  7. Stephen

    Stephen Long timer Supporter

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    And isn't it true that in 03 the bottom frame rail was modified (i.e, bent :lol3 ) to make it easier to renew the oil filter?
    #7
  8. FlyinGo!!!!!

    FlyinGo!!!!! Ride it like a two stroke

    Joined:
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    Newport Beach
    Thanks for all the input. I have a client looking to buy soon and trying to decide between the 640 and the 950 and he is looking for used, so learning any differences is very helpful to him. Thanks! I now return to myself to "Orange Crush".
    #8
  9. creeper

    creeper Still alive...

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    That change occured in the mid '02 model year... as far as we can tell. :D
    #9
  10. Surly

    Surly surly adventurer

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    As long as your wearing a dress and pointing a shotgun at me I will agree :rofl

    Otherwise you are off a few years!...and I think you know how many :lol3
    #10
  11. daotoys1

    daotoys1 Long timer

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    The bottom frame craddle mod to allow easy access to the oil filter is a 2002 change....my 2002 KTM LC4 640 AdventureR has this update...
    #11
  12. Nom de Guerre

    Nom de Guerre Long timer

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    Dress or no dress, Mr. Loaded is correct. Sorry for the rest o' you suckers. :D It is well known among the LC4 aficionados that KTM is struggling to find the magic they achieved in the near perfect '02 model (perfect once you've done the bearing swap)

    Oh yeah, doesn't the '05 (may have started in '04) have an added oil injector under or by the piston?
    #12
  13. The Misinformant

    The Misinformant What road?

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    03-04
    Apart from colours and the front end. They changed the auto decomp components but not design from 03 to 04. 03 build bikes had auto decomp problem were it was slipping below about 3000 RPM. They started to fault from around 4000 kms. All were fixed under warranty and the new upgraded part numbers matched the 04 part numbers for camshaft and decomp parts.

    Rest pretty much the same mechanically.
    #13
  14. meat popsicle

    meat popsicle Ignostic

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    hm, this is new info - got a service bulletin number on that? :ear
    #14
  15. ChrisC

    ChrisC Amal sex?

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    Would that be the '02 model with the Lo-Flow head and the funny paint scheme? :lol3
    #15
  16. overlandr

    overlandr Dystopist

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    Seems like we've got the seed beginnings of a KTM 640 ADV FAQS here - keep it up guys :D :D
    #16
  17. Velocibiker

    Velocibiker Adventure Antagonist

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    I do believe some judisiously applied spray on bed liner covers it up nicely though..

    Oh yeah. I'd forgot about that nice little oil site glass.


    gaspipe:: Different dash? ummmm... I don't know about that one.

    A quicky scan of the '03 fische shows the exact same part numbers for all the cockpit parts except the cockpit cover itself. Since the '03s have the power outlet on theirs, that makes sense. Everything else is the same '02-'03.

    Digging a little more shows something odd. The '03 fische shows the '02 "multi-func-digital-speedometer". If you look at the '04 fische, it has a different part number and it implies it was for the '03: "DIGITAL SPEEDOMETER 03". My guess is that they used up the current inventory of '02 speedos and then introduced the '03 speedos. So I guess it's possible to have an '02 or '03 speedo on your '03+ Adventure.

    Crap. More info then I really needed :lol3 I wonder what the difference(s) are?????
    #17
  18. Nom de Guerre

    Nom de Guerre Long timer

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    Ah... That would be the '02 model with the "Right Flow" head. Didin't you know that KTM introduced the so called "Hi Flow" head in a vain attempt to offset the anticipated performance draining side effects of the additional breathing restrictions (SLS) they implemented in the '05 model?:rofl J/K, Surly and the rest of you '05 owners.

    As for funny paint scheme, I wouldn't know. Mine is now Silver and Black. Very much looking (and acting) the business as they say. All orange plastic bits are on the shelf for the time being.

    Cheers, from London :1drink
    #18
  19. ChrisC

    ChrisC Amal sex?

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    .
    #19
  20. Nom de Guerre

    Nom de Guerre Long timer

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    '03 = Penultimate?

    Perhaps (see definition below). I merely stated that the '02 is best. Where it all shakes down after that is academic.:snore

    Sounds like the '03 paint scheme.

    Similar, but with a much cooler tank paint job that graduates to black at the bottom. :evil

    penultimate
    adj. Next to last
    n. The next to last
    From the Latin, penultimus

    So as you see, you just may be right about that '03 being the penultimate LC4 :rofl

    Don't be mad. I still love ya pookums :poser :rilla

    Sorry for the hijack... it's late at night here, and I miss you guys :cry
    #20