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Old 02-21-2013, 05:37 PM   #1
rtwpaul OP
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KTM - LC4 Round the World ADVenturization

calling on the vast knowledge base that is ADVrider.com to help me out and get my new (to me, only 500 miles on the clock) LC4 ready to ride around the world...so please chim in, comment, recomment, if you're local stop by (Vegas), add your photos, suggestions, regrets, secrets etc. etc.

just picked up a 2003 KTM 625sxc to continue my RTW (see my signature line for the ride report) 63,000 miles done so far on a Yamaha XT660Z Tenere


what i have been unable to find is any photos of a bike that has added an auxiliary oil tank, i have found lots of threads but no photos...ANYONE??????



so here is a list whats been done by the previous owner ...

1. Carb: BST Mikuni stock carburetor with slide drilled out
conservatively. I did not go to 1/8 but something a little less and that
seemed to add some nice snap along with a complete tear down and cleaning.
I also terminated two of the breather lines with K&N air filters rather
than re-breathing spent fumes. Replaced the four bowl screws with hex
screws.
2. Airbox no longer has water overflow, crank case and fuel over flow
(all from main chassis collection point) dumping into it. Apparently that
made the box a little gummy and also the carburetor. Much cleaning
operation now. Have new air filter but not installed as I cleaned the
original one off (not too many miles on it).
3. Changed the oil used new KTM oil filers. I believe I used Yamalube.
4. Lighting installed LED markers all around and updated head lamp for
High and Low beam operation. There is some non-insulated wire coiled up
behind the headlamp. This is ground and its copper so no need to insulate.
5. Checked all four valves. Intakes were off just a little tight.
6. New Continental TC80 tires front and rear less than 150 miles.
7. New lead acid battery.
8. Have auxiliary factory seat that lowers the ride height and and can
be sued to customize as needed.
9. Added duel mirrors and bar mounts and have the original factory
folding mirror. Now you have an aux 10mm mount on the handle bar for GPS
etc.
10. All manuals and have two exhaust gaskets, Motion-pro feeler gauge



and this is a short version of why i bought it...and at the bottom photos of the bike



so the Yamaha Xt660z is alive and well and taking a well deserved siesta, but i wanted a change (actually once this is complete the XT will go up for sale)

as a RTW rider you kind of learn as you go along, with roughly 200,000 touring miles under my belt, 63,000 in last 22 months you come to conclusion that you will read here and everywhere else, i wish i had a lighter bike. There are a lot of places that i have missed, some i have tried and failed to get to simply because of the weight of the bike, all the guys riding the heavy weights wished for mine, i wished for less.

The reason being; i am heading to New Zealand, then Australia, the Far East, the Stans, Russia, Mongolia and eventually Africa...are you seeing where i'm going with this thought pattern, lots more dirt in my future

the XT660 is the heaviest in its class but very durable too, but once you add luggage, and i am a light packer you still have a lot of weight, not GSA standards but restrictive weight.

so i started looking at other options for when i carry on RTW, i posted on a few forums about what i was looking for, light weight, good power, options to add a very large gas tank, reliability and so on to get some other riders input

the short list came back as:

WR250R
XR650L
DRZ400
DR650
KLR650
570 husaberg
610 husqvarna

now other requirements for a RTW rider is shipping and import, what does this have to do with bike choice? Well a lot actually, obviously weight and the ability to reduce the bike to the smallest size possible and Carnet, the fees can get outrageous in some countries for import, so expensive bikes cost a fortune to bring in to some places - calculate your current bike to see what i mean...Carnet price calculator link

The WR250R was top of the list for a while with the DRZ400 in very close second, but finding a good used one with minimal miles was not happening, and a new one by the time i added everything i needed i would be pushing the $10k mark, why not just keep riding the XT i was asking myself

...then out of the blue some guy makes a comment, have you looked at a KTM 625 SXC, it's everything you are describing, all the other bikes to be made RTW ready would cost more in the long run, the KTM has a good level of components as stock, you can get a 27 liter tank, (you could add a rotopax that will be empty 99.9% of the time to opposite side of the exhaust can, taking it up to 31 liters)

it has minimal electronics, so less to go wrong, no fuel pump, no FI etc, only problem is they only made a few and getting a low mileage one is virtually impossible, and most owner once they buy never sell

so doing web searches on all the above bikes i came across a 625SXC with only 500 miles on it, the owner was having some health issues and never rode it. As its a 2003 the book value is minute (great for the Carnet) and he had done a lot of mods already to save me additional time and money...it weighs about the same as a WR250, double the power, i can get a tank that's 2.5 gallons bigger than the biggest for the WRR

so i pulled the trigger and now i have gone orange and i'm proud owner of a basically new (to me) LC4... in the coming months it will go thru a transformation to be made RTW ready - any comments/ suggestions/ recommendations/ farkle lists would be gladly accepted



after my four mile test ride
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Old 02-21-2013, 05:47 PM   #2
biensur22
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Top of your list should be a new seat. Looks like a nice bike though, good luck!
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Old 02-21-2013, 05:58 PM   #3
rtwpaul OP
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Originally Posted by biensur22 View Post
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Top of your list should be a new seat. Looks like a nice bike though, good luck!
I have been looking at that for sure, nothing "off the shelf" out there that i could find, open for recommendations for good seat guys? or is there seats from other models that would fit...comfort seats etc?
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Old 02-21-2013, 06:04 PM   #4
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Originally Posted by rtwpaul View Post
I have been looking at that for sure, nothing "off the shelf" out there that i could find, open for recommendations for good seat guys?
Since you're in Vegas, you should drive out to Hemet, CA and pay Lendon and Robert a visit at Seat Concepts. I've got one strapped on my 620Adv and let me tell you, nothing beats it for the same money. They also have a in-person cash price that could save you a few bucks. Give them a bit of notice and they'll get whatever cover you want made (carbon fiber, gripper, suede, etc) with special stitching if you want (ORANGE!). They can also do lower seats and I believe different densities of foam for softer/firmer rides. Again, best bang for your buck by far.

I'd also suggest a set of Highway Dirtbike handguards with their top-clamp mount. Awesome system, very versatile and adds a great deal of rigidity to your cockpit.
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Old 02-21-2013, 06:07 PM   #5
biensur22
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I should also mention that you'll want to subscribe to the lc4 index thread and read through all the engine maintenance/modifications. lc4 motor is extremely reliable, but there are a few bearings you'll want to keep your eye on, as well as the water pump, among other things.
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Old 02-21-2013, 06:17 PM   #6
rtwpaul OP
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Originally Posted by biensur22 View Post
I should also mention that you'll want to subscribe to the lc4 index thread and read through all the engine maintenance/modifications. lc4 motor is extremely reliable, but there are a few bearings you'll want to keep your eye on, as well as the water pump, among other things.
the water pump has been done, but the question is what is the real cause and can it be corrected permanently or over time will it always be an issue?

as for bearings when replacements are done are the factory KTM ones the best way to go or is there a source for a higher standard that has worked better?
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Old 02-21-2013, 06:12 PM   #7
rtwpaul OP
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Originally Posted by biensur22 View Post
Since you're in Vegas, you should drive out to Hemet, CA and pay Lendon and Robert a visit at Seat Concepts. I've got one strapped on my 620Adv and let me tell you, nothing beats it for the same money. They also have a in-person cash price that could save you a few bucks. Give them a bit of notice and they'll get whatever cover you want made (carbon fiber, gripper, suede, etc) with special stitching if you want (ORANGE!). They can also do lower seats and I believe different densities of foam for softer/firmer rides. Again, best bang for your buck by far.

I'd also suggest a set of Highway Dirtbike handguards with their top-clamp mount. Awesome system, very versatile and adds a great deal of rigidity to your cockpit.
i tried to get them to come to Overland Expo last year but they couldn't make it, so i guess i will go to them like you suggest

i have barkbusters already mounted on some renthal bars (on the XT) that i will probably swap to as the ride height on the XT was perfect so hopefully it will work on the KTM too
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Old 02-21-2013, 06:06 PM   #8
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If you go with the big tank (28L) I am pretty sure you will have to change the seat, so you may want to get the fuel sorted before spending money on the seat.

The best is Renazco, but Seat Concepts do a few KTM seats and have got good reports.

Make sure you let us know when you are about to hit Australia and NZ.
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Old 02-21-2013, 06:14 PM   #9
rtwpaul OP
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Originally Posted by dnrobertson View Post
If you go with the big tank (28L) I am pretty sure you will have to change the seat, so you may want to get the fuel sorted before spending money on the seat.

The best is Renazco, but Seat Concepts do a few KTM seats and have got good reports.

Make sure you let us know when you are about to hit Australia and NZ.
i kind of figured there maybe an issue, maybe with the fit too so yes i'll get the tank first and then move forward fromthere with the seat, then bars and wind protection etc

for sure i'll contact you when i get back into the southern hemisphere, any website suggestions for places to go, good tracks etc would be appreciated as well so i can plan a route and beer stops
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Old 02-21-2013, 10:45 PM   #10
biensur22
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Originally Posted by huzar View Post
She's dreaming about a lowered seat dr650? First I've heard of it. Damn it, why I am I the last to know



I'm guessing there will be another 650GS in her future, maybe one with a factory lowering kit? I'd talk her into the F800GS, but that bike is taller, and besides, with that much power, there's no way I'd ever catch her

I'll be keeping an eye out for an XT225 or XT250 for her for here, so we can go do some dirt riding together. That yellow piggie of hers doesn't do so well in dirt.
I was just reading about the new f700gs in this months motorcyclist magazine. Worth a look - restricted f800 power plant, optional 30" seat height, etc
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Old 02-22-2013, 12:02 AM   #11
Lc8grrr
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Unless I missed it and your bike has one already (but being an earlier SXC probably not) is a cush drive rear hub as on an ADV or 640E. Probably save gearbox issues down the road..
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Old 02-22-2013, 07:31 AM   #12
rtwpaul OP
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Originally Posted by Lc8grrr View Post
Unless I missed it and your bike has one already (but being an earlier SXC probably not) is a cush drive rear hub as on an ADV or 640E. Probably save gearbox issues down the road..
this is one of my things to do for sure, i have been looking at RAD manufacturing to make up a set of rims for me, little spendy but way cheaper than transmission replacement
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Old 02-22-2013, 09:49 AM   #13
Adv Grifter
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Originally Posted by rtwpaul View Post
this is one of my things to do for sure, i have been looking at RAD manufacturing to make up a set of rims for me, little spendy but way cheaper than transmission replacement
Or maybe take a look at DID Dirt Star rims. Very highly regarded over Excel and others.

Good group of KTM experts here. Have fun with the build!

Does your BST Mikuni have an extended Fuel/Air screw? Very handy, easy adjust at altitude for better starting, idle and low speed running. Helps with MPG too.
(The DR650 has the same carb ... so I've messed around with them a bit)
You can try different needle tapers too. Put some sort of decent (but NOT restrictive) fuel filter as BST pilots clog easily. (carry a spare pilot jet)
If tuned properly you should get decent performance ... and good MPG. (open air box top helps on the DR)

Adv Grifter screwed with this post 02-22-2013 at 10:10 AM
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Old 02-22-2013, 01:55 PM   #14
rtwpaul OP
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Originally Posted by Adv Grifter View Post
Or maybe take a look at DID Dirt Star rims. Very highly regarded over Excel and others.

Good group of KTM experts here. Have fun with the build!

Does your BST Mikuni have an extended Fuel/Air screw? Very handy, easy adjust at altitude for better starting, idle and low speed running. Helps with MPG too.
(The DR650 has the same carb ... so I've messed around with them a bit)
You can try different needle tapers too. Put some sort of decent (but NOT restrictive) fuel filter as BST pilots clog easily. (carry a spare pilot jet)
If tuned properly you should get decent performance ... and good MPG. (open air box top helps on the DR)
thanks i'll look into the rims and as the post after yours says the stock cush drive rear wheel is a good option with the 2.50 rim

once i pull the carb off i can note what i have and get spares from there onwards
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Old 02-23-2013, 02:47 AM   #15
Lc8grrr
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Originally Posted by rtwpaul View Post
this is one of my things to do for sure, i have been looking at RAD manufacturing to make up a set of rims for me, little spendy but way cheaper than transmission replacement
I have a couple of Talon cush drive rear wheels but probably wouldnt use one on a ride like yours as the rubber inserts are a smallish O ring (maybe RAD use something better) The factory Rally bikes of Despres/Coma/Sala etc used a Talon front hub but a KTM OEM rear hub which uses the same rubbers as on a 640A or 950A. That to me says the OEM is much better for lots of abuse or lots of miles.
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