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Old 07-09-2005, 06:34 AM   #1
meat popsicle OP
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Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
Oddometer: 14,260
KTM LC4 (640) Thread Index

REVISION DATE: January 20, 2014

This is a thread index for many of those great posts by La Familia, with some crap thrown in for balance. This is by no means definitive, so PLEASE reply to this thread with your favorites threads, or suggestions on removing threads, etc, and we may append, edit, delete, and so forth. I thought this would give those who redundantly point to this thread or that one an easier route. Please note that all External Links are marked with the following red note. External Links! AdvRider is not responsible for anything at these links; proceed at your own risk. As before, newest additions will be in Orange for a spell.

NOTE: If you can't find a thread you are looking for, please post your request to this thread and we will try and help you find it. If there is no existing thread to join, then start a new thread in Thumpers to fill the void.

One tip for searching this thread, try using your web browser’s page search function (usually pushing CTRL and F at the same time will bring it up, or try the Edit menu on the toolbar) - it will save you some time. A suggestion for searching Thumpers is this: CLICK HERE and then add your search terms to the search and Google will only search this site. It is a great tool for searching this site with 3 letter terms.

Also, please be aware that this is not a FAQS page. Although QA/QC edits are ongoing in an attempt to not lead anyone astray, people should use their best judgment and if in doubt ask questions! Of course you should ask your specific question in a different thread... the point of this thread was not to make questions unnecessary; the point is to help end the relentless search for "those" thread links. However, there are some "How-To's" that are very well respected and I think could be considered FAQS. Those highly regarded how-to-do-it threads are now in their own section at the beginning of this thread. If you disagree with an inclusion, submit your complaint to the committee.

Oh yeah, and one other thing that might help us help you: Hi n00b, welcome to ADVrider. Got a question do ya?

So here is Part Juan of the index:
Links Useful to Everyone


Meat's old Yahoo Briefcase file share now on Google Drive

Crazybrit's Installing a fan on the 625 SXC

Laramie’s BST-40 Bible

Meat Popsicle’s How to service (some) LC4 forks

Creeper's Looking at a used LC4?

Neduro's Spring Bike Maintenance and Setup Guide

Luke's Stators Demystified

LaramieLC4 Engine Removal/Replacement

loisu’s LC4 640 starter clutch fix

Dirty Sanchez’s KTM 640 Adventure HID Upgrade w Centech

Laramie LC4('s) Steering head bearing, a how-to-guide...

Creeper's DIY Brake Service Guide

LC4 Pilot’s Rebuilding the LC4 Mechanical Water Pump - a Guide

Meat Popsicle’s Guide to changing your chain and sprockets on the LC4

Creeper’s Servicing the LC4 Chassis Swingarm Thread

Creeper's LC4 Sprocket Seal Replacement

Creeper’s Re-sealing the KTM LC4 Rocker Cover
and his note: when is a rocker cover leak not a rocker cover leak?

Meat Popsicle’s Kick Starting the Beast

Creeper’s Valve Inspection
Creeper's Finding TDC-C

Neduro's Tire Changing Class

CountPacMan's (hopefully) Definitive CDI Guide

Creeper’s Oil Change

markjenn’s LC4 Bearing Upgrade

Tseta's Three times the fun! (LC4 HOWDID)

Tseta's Routine maintenance (LC4 HOWDID)

1. Engine, Transmission, and Drivetrain

1.a Discussions

Creeper's LC4 Setup Thread

Creeper's old post on setup

And some other threads on setup
Gaspipe’s Setup (and mod discussions!)
Neduro's KTM Setup Thread
Accessing the Holy BST
What to get (and do) first for my new LC4 - a discussion Including side airbox mod pics!
desmonc's 05 LC4a thread tons of setup and mod pics (and discussion)
Another mods discussion thread

How do I properly Break-in the LC4? – think some loudmouth on the internet know better than your bike’s manufacturer?

Emissions controls the world over... and threads that offer "deactivation" assistance.
SAS removal outside the USofA thanks Sylvia!
Derestricting a 2006 SMC
Links to Dealing with the Evaporative Emissions "afterthoughts", and SAS
EPC (Electronic Power Control) design and deactivation.

An Oil Thread…

Idle RPMs
Idle Hunting?

640 Adv / CS Sprocket / Loctite ? (CS sprocket discussion)
Good CS Sprocket maintenance discussion

Why my bike don't go over 85mph anymore - a discussion

Coolant Thread
cool is a state of mind, not fashion

1.b Repairs

Clintnz's 95,000 service

Gunnerbuck's 640s 127,000 service

640 LC4 Adventure 'bleeding' oil on head gasket? – with repair ideas from Creeper

Creeper's Chain Alignment Tool

Creeper's Radiator Removal Tips (yep, he was bored again)

Clutch Noise? With link to the KTM Tech Bulletin on:
Tightening Procedure For Balancer Shaft Assembly Bolts On 2003 LC4 Engines (thanks dirtrider! )

Got Milk?

A little birdy’s chain adjustment thread

1.c Mods and Upgrades

LC4 Owners Poll: Premium coolant hoses

Loaded’s Gearing Thread

2. Carburetion, Exhaust and Other Highly Contested Subjects

2.a Discussions

External Link! General Carbureator Theory

Which carb is best on LC4 640 – with a discussion of BST maintenance

To Clip, or Not To Clip… That is the question

BST Needle Help

Creeper’s LC4 Exhaust Thread

LC4 Exhaust Sound Testing Thread

2.b Service and Repairs

640 LC4 Sprocket Seal Question?

Setting the BST's Carb Float Height
KTM 640 Float Spring Replacement?

Tool: Float Height Cage Holder


MaxAir's guide to setting float height (w/tool)

Float Height Importance in Carb Tuning

Factory Pro's guide CV Carb Tuning
And of course Mikuni’s Tuning Guide

2.c Mods and Upgrades

BST Mix Screw Threads
BST 40 Idle Screw

creeper got bored again... KTM LC4 Mikuni BST40 Venting
Bernoulli's Law of Carb Venting – curiosity killed the cat
and one more on carb venting

3. Chassis (Bodywork) and Controls (Cockpit)

3.a Discussions

Converting a pre-03 Clutch to Hydraulic with a link to and the Secrets of Magura

Handlebar Controls and Cable Routing
Adjusting your throttle cable

Ergonomics or Bar Height, Seat Height, and Peg Height?
Stock 2003 LC4 ADV handlebar Bar name/rise?
Aftermarket bars on 640A

IMO Threads
the solution to an overheading 640 adventure...
KTM 640 adventure Tripmaster LCD (broken)
Neutral Light Always on. '06 640 Adv

3.b Service and Repairs

KTM Adventure-Steering head bearing adjustment

KTM 2003 LC4 clutch lock-out switch

Broken centerstand blues…

Hydro clutch issues

3.c Mods and Upgrades

Reviews of Renazco Racing Seats
meat popsicle

A Rad Review of Guts Racing Seats
Review of Bill Mayer Saddles
Review of Russell Seat

A Discussion on Grips

04 and later High Fender Conversion Thread (links therein)
KTM 640 Adv '05 - High Front Fender !!!
Low Guard/Brake-line Recall 04-05Adventures?
640 High Guard Mod-04,05,06 they'll change it in 07!
640 High Fender
640 High Fender Mod (fork guard fix!)
Trying to keep the 640 low fender...

PASSMORE's pre-2003 Centerstand Upgrade Thread

Bar Riser’s
Risers... Pennytech, Touratech, Sommer, etc?
"Quickie" KTM bar riser extensions

Mirror Threads
Mirror mirror on the wall...
Installing Dual Star Mirrors on a 640

Bark Busters (aka Handguards)
Thread index, No Bark Busters?

LC4 footpegs
Scott Harden School & Lower LC4 E Pegs
KTM Rally Peg dimensions???

4. Electrical

4.a Discussions

Kick-starting LC4 with dead battery? – disconnect headlights!

Repost of Flanny’s LC4 electrical output post

How to wire into '03 LC4 640 accessory outlets? – and discussion of stock wiring issues

EXTERNAL LINKS: Stock Wiring Upgrade?

I need more power Mr. Scott!!!
I need more lighting Mr. Scott!!!
KTM 640 Adv illumination

How to wire both headlights on together (thanks warewolf!)

4.b Service and Repairs

LC4 Starter help? - with JayBo1’s rewiring out the safety interlocks

03 KTM 640 Adv -- Electrical Problem (check your ignition switch)

Creeper’s LC4 electrical diagram breakouts

Troubleshooting the Charging System (faultchecking)

LC4 Starter - Repair or Replace?

4.c Mods and Upgrades

Loaded Wiring Handwarmers

Long term opinion of Trail Tech, and electrical troubleshooting of them

5. Suspension and Wheels and Brakes

5.a Discussions

Ever wonder about fork oil?

Zerodog’s Ever wonder what is inside your 640 shock?

Stock Behr rims (2004 - LC4s)

A Tire Thread (more in Post #2)
Rear tire for my 640?
Creeper’s Inner Tube Thread

Forks and Shock
Fork Oil and Suspension Questions
Heavier spring for 640 adventure?
Stobie’s spring recommendations
640 Suspension question (SAG)
Sag numbers for 02 adventure
What are stock spring rates in 01 ADV?
640 Adv stiffer rear spring/forks
640 Adv suspension settings
640 Adv suspension settings; buckster double shot!
Don’t be distracted by the float questions, they are talkin’ springs too
LC4 Suspension: To revalve, or not to revalve?
Sommer KTM’s recommendations
spring diameter issue
The Spring Quest
Fork Maintainence, complete or routine?

Front End Wag Question

5.b Service and Repairs

boyscout’s LC4 steering head and fork service notes – new class of thread: summaries?

Servicing the Forks
LC4 fork oil level?
KTM LC4 Fork Oil Change
Servicing the Fork Seals (thanks Surly! )
cleaning fork seals

Air in Front Brakes?

Spokes – Love‘em or Hate’em; its up to you (more in Post #2 on spokes and brake squeal)
Spoked Wheel Maintenance
KTM 2002 Tech Bulletin on Spokes
KTM recall on front wheels
LC4 Enduro/SXC spoke recall

5.c Mods and Upgrades

Infinity Subtanks on a 640
Fork subtanks... are they for you?

6. Other

6.a General Discussions

Why Clean Your Bike

The LC4 Skidplate Thread (and skidplates in general)

KTM Adventure Threads
KTM 640 Adventure (and LC4) owners, sign in please...
Extinct KTM Shoot the Shite Threads
I'll Show You Mine If You Show Me Yours
New "General Purpose KTM'ers thread"...
General purpose KTM'ers "shoot the shit" thread
TONS OF INFO LOST IN THESE THREADS – THEY NEED TO BE INDIVIDUALLY INDEXED. (simply review the threads and add a post to them with a Table of Contents, linking to stuff in the threads, and I will link to your TOC)

LC4 Enduro Threads clintnz's upgrade threads added
KTM LC4 Enduro Model History
640 Enduro Windscreen
640 Enduro Radiator Guards
KTM 640 Enduro

Dukes? (It’s a beginning…)
Got a new Duke, Pictures and Questions within.

SXC?(Again, it’s a beginning…)
KTM 625 sxc (general)
KTM 625 SXC -- Anyone installed an extra oil cooler or reservoir ?
DIY Add a Bleed Screw to your Banjo Bolt (for SXCs and other LC4s w/out oil in the frame)
Question about KTM 640 ADV tank/fairing (on a SXC).
Alternatively: Smaller gas tank for a 640 Adventure
KTM 625 sxc 4 me?
Bigger tank help needed KTM 625 SXC
Milky coolant everywhere!!!
Antifreeze in '01 Adv.
SXC/LC4 BMW windscreen

SMC Threads
Anyone own a KTM 625 SMC?

LC4 Owner's Manual and Engine Service Manual Links
LC4 manual on CD - FREE

Other external links to stuff

6.b Services and Repairs

Tools, Toolkits, and Related Widgets
The Toolkit Thread - hilslamer
What is in your KTM 640 tool kit?
KTM 640 Adv - Tool box options
KTM 640 Adventure, what spares to carry?
toolkit pics
'05 640 Adventure Tools Question
spark plug socket

Torque Wrench Thread

Loctite Thread

Toolbox Ideas
LC4 toolbox
Tool Box Idea for the KTM LC4
KTM LC4 Toolbox Tabs FIX?

6.c Other


KTM 640 Adventure luggage options explained

jimjib's Threads (pics gone?!? )
mounting pelican cases
mounting larger pelican cases

Other Threads
clintnz's custom soft pannier braces
another post on pelican cases
Ricardo's thread on attaching pelican cases
general 640 Adventure Luggage thread

LC4 Pilot's Searches
Zega Vs. Moto-Sport Aluminum cases
Pelican setup for 99 640 Adv R
general KTM Adventure Hard Luggage thread
640 Adventure luggage?
640 Adv and Happy Trails bags

Soft Bagz
Andy Strapz Bags - Quick Review
soft panniers for KTM640 adventure
general Soft Luggage thread
KTM 640 factory racks (maybe not a soft bagz thread...)

Tank Bagz – thanks ChrisC and Velocibiker and sherpa!
general Tank bags thread
The quest for the (cheaper alternative) KTM Adventure tank bag
Wolfman Explorer Lite/Enduro Tankbags fitted on KTM 640 Adventure (sherpa showing how a review is DONE.

AdventurePipe’s Pelican Case Customized Luggage and Racks
New Pelican-based Luggage System (LC4 covered?)


Velocibiker's Pennytech Light Guards

Composite Materials Tankguards
Ok - Adv. Skid Plates $300 Usd - Flanny Manufacturing (NOTE: OLD THREAD!)
140 $ Carbon Kevlar 640 Adventure TankGuards (NOTE: PLAN NEVER COMPLETED)
ISO a CF/Kevlar artist

Adventure 640 tank guards/trip pics (Hepco Beckers – questionable kit…

More Tank Protection
How to protect KTM LC4 Adv without tank bars?
KTM Adventure crash protection
640 Adventure tank bars

LC4 Cock Protection

Rallye Skidplate Boxes
KTM 640 Rallye skid plate (Group effort) – died off; my fault
Adventure R rally skid/storage plate

More Skidplates
Review: KTM LC4adv CF skidplate
Kronreif Trunkenpolz Mattighofen LC4 640

Its not so much staying alive; its staying human that counts.

meat popsicle screwed with this post 04-23-2015 at 06:36 AM Reason: creeper
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