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Old 05-18-2013, 08:55 AM   #3901
meat popsicle OP
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Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
Oddometer: 14,177
aftermarket wiring? The most likely would be to bypass the stock headlight circuit with heavier gauge wiring (so they are properly fed); if that's the case then the lil' white box would indeed be a relay so the circuit is switched by your key.

You can get owner's manuals from KTM:
http://www.ktm.com/us/faqs.html
(older than 2000 via the dealers)

The shop manual is a purchase item from KTM, but you can also find it via some 3rd party downloads (user beware!).


Quote:
Originally Posted by psychocandy View Post
Hey all,

So just recently, my high beam stopped working. I thought it had just burnt out since I used the high beam all the time since the light output from the teeny enduro headlight is a bit less than what I'm used to.

But the bulb was fine and I noticed that high beam works when I use the little flasher/passing button on the headlight switch. My fuses look to be good, although there seems to be some creative after market wiring involved. I'm wondering if the flasher bypasses the high beam relay.

I don't have the manual for my bike, or a wiring diagram. Is that little white box behind the headlight with 4 contacts the headlight relay. I know the wiring on these bikes is pretty simple, but it's all kinda packed into the tiny headlight shell and I don't wanna unravel everything and potentially cause more problems.

Advice?
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Old 05-18-2013, 12:21 PM   #3902
vburgh
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Originally Posted by bmwktmbill View Post
Wamt 'em? Got 'em for the '02 stock muff for postage.

bill
Thanks Bill I found some today local.
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Old 05-19-2013, 05:01 PM   #3903
Tonicu
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Front sprocket shaft play

I arrived this afternoon from a very much enjoyed morning excursion into the nearby woods. Carburettor problems and stalling sorted out, a worn slide, float and needle being the culprits.
So after cleaning the bike, when I was about to oil the chain I noticed quite a lot of play in the rear sprocket - the bearing being the cause, I guess - and more worrying, I also noticed some axial play on the front sprocket shaft. I changed the sprocket seal about one year and 10k kms. ago and by then there was no noticeable play.
Er ... if the shaft inner bearing needs a replacement does it mean I'd have to take the engine apart ... completely?
From what I've read, the f/s axial play tolerance is 0.4mm. I'd say it's around or perhaps a bit more than that.
My LC4 is a '03 640E with 49k kms on the clock.
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Old 05-19-2013, 08:41 PM   #3904
clintnz
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Quote:
Originally Posted by Tonicu View Post
From what I've read, the f/s axial play tolerance is 0.4mm. I'd say it's around or perhaps a bit more than that.
My LC4 is a '03 640E with 49k kms on the clock.
They go great with a freshened up carb don't they? the wear happens slowly so you don't realise how crappy the fuelling has got.

When I rebuilt my motor the axial play on the countershaft was at the limit - with new bearings - I double checked everything but couldn't find anything wrong. It's done 25K km since with no problems. Maybe get an accurate measure of it then check again after a few hundred km. Make sure the engine is at a similar temperature to get a good comparison.

Cheers
Clint
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Old 05-20-2013, 09:40 AM   #3905
F1paul
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Joined: May 2013
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Question ktm 640 supermoto FSM

anybody have a FSM for the 640 motor that they would like to share?

i have recently noticed oil leaking from behind the front sprocket.......i have only had the bike for three months and just this week started noticing oil spray on the rear wheel and a few drops of oil on the ground under the engine of the bike after sitting a hour or so.
i took the plastic cover off where the front sprocket is and looks like it is coming from somewhere behind the sprocket.....is there some kind of gasket or something there that would be leaking?
i havent taken the sprocket off yet because i am using the bike for work and it is beatiful weather right now in toronto.
plus i dont want to attempt without an FSM before buying required part and having my bike out of service.

also the owners manual does not say what the sight glass is on the right side of the motor ..... i know the left side with the two hash marks is the oil fill level but can anybody enlighten me what the right side is for...because it is not showing anything inside...i believe it is crankcase oil also but does not show anything until the bike is started.


thank in advance........Paul.
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Old 05-20-2013, 10:22 AM   #3906
Gerst
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Quote:
Originally Posted by F1paul View Post
anybody have a FSM for the 640 motor that they would like to share?

i have recently noticed oil leaking from behind the front sprocket.......i have only had the bike for three months and just this week started noticing oil spray on the rear wheel and a few drops of oil on the ground under the engine of the bike after sitting a hour or so.
i took the plastic cover off where the front sprocket is and looks like it is coming from somewhere behind the sprocket.....is there some kind of gasket or something there that would be leaking?
i havent taken the sprocket off yet because i am using the bike for work and it is beatiful weather right now in toronto.
plus i dont want to attempt without an FSM before buying required part and having my bike out of service.

also the owners manual does not say what the sight glass is on the right side of the motor ..... i know the left side with the two hash marks is the oil fill level but can anybody enlighten me what the right side is for...because it is not showing anything inside...i believe it is crankcase oil also but does not show anything until the bike is started.


thank in advance........Paul.

For the leak I'd start here http://www.advrider.com/forums/showthread.php?t=102920

I believe the sole purpose of the right side glass is to see the timing mark
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Old 05-20-2013, 10:56 AM   #3907
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Quote:
Originally Posted by Gerst View Post
For the leak I'd start here http://www.advrider.com/forums/showthread.php?t=102920

I believe the sole purpose of the right side glass is to see the timing mark
I believe the sole purpose of the right side glass is to keep the oil companies in business.

1. i've never been able to see a damn thing through mine; and
2. it seems impervious to sealing.

[replaced my stator with the electrosport upgrade (commence flaming ) this weekend and tried sealing the sightglass again (probably the third time). i did a much better job of cleaning and allowing the sealant to set, so fingers crossed!]
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Old 05-20-2013, 11:50 AM   #3908
Syncrosimon
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Hi,

I have play in the lower shock bearing on my 99 LC4 400D.

The KTM part number is

54203083050 HINGE BEARING BLASTED £45.48

And with seals and a new grease nipple it all comes to £80.

Is any one aware of an aftermarket replacement. I cannot find an All Balls replacement at half the price, but surely KTM used the same bearing on other models.

Also, does it just hammer (sorry I mean Press!) out??


Thanks for your help.

Simon
KTM LC4 400 ford crossing photo IMG_0130_zps69ff1555.jpg
KTM LC4 400D photo P1010898_zpsa8bac193.jpg
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Old 05-20-2013, 11:57 AM   #3909
drdfblackm
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Little Help??

I am starting to think that an LC4 bike might be my next one...maybe. Can someone talk about ins and outs of 640 Adv vs 640E vs 625sxc.

I am going to be doing long distance off road....slab will be involved getting from one section to another. Some will be tighter and rocky but I was able to do it on a DR650 easily. I have owned just about everything and the my latest DR650 did well but is not tall enough....pivot leg hits immediately when I corner. Need a taller bike (I am 6'4" at 228lbs)

Let me know what you think or if I am barking up the wrong tree.
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Old 05-20-2013, 12:30 PM   #3910
mountaincadre
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Quote:
Originally Posted by Syncrosimon View Post
Hi,

I have play in the lower shock bearing on my 99 LC4 400D.

The KTM part number is

54203083050 HINGE BEARING BLASTED £45.48

And with seals and a new grease nipple it all comes to £80.

Is any one aware of an aftermarket replacement. I cannot find an All Balls replacement at half the price, but surely KTM used the same bearing on other models.

Also, does it just hammer (sorry I mean Press!) out??


Thanks for your help.

Simon

You are a filthy pig, ktm forum, one of the reprobates should have one kicking about, failing that get the bearings from somewhere else.
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Old 05-20-2013, 01:57 PM   #3911
Syncrosimon
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Quote:
Originally Posted by drdfblackm View Post
I am starting to think that an LC4 bike might be my next one...maybe. Can someone talk about ins and outs of 640 Adv vs 640E vs 625sxc.

I am going to be doing long distance off road....slab will be involved getting from one section to another. Some will be tighter and rocky but I was able to do it on a DR650 easily. I have owned just about everything and the my latest DR650 did well but is not tall enough....pivot leg hits immediately when I corner. Need a taller bike (I am 6'4" at 228lbs)

Let me know what you think or if I am barking up the wrong tree.
The LC4 is a nice tall bike. I think it is a very good all rounder. Much more supple off road than my XT660Z Ténéré, but more vibrations. The Ténéré feels like a road bike in comparrison. The LC4 is as solid as they come, and feels like it is hewn out of granite.
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Old 05-20-2013, 02:27 PM   #3912
clintnz
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Location: Rotoiti, New Zealand
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Quote:
Originally Posted by Syncrosimon View Post
Hi,

I have play in the lower shock bearing on my 99 LC4 400D.

The KTM part number is

54203083050 HINGE BEARING BLASTED £45.48

And with seals and a new grease nipple it all comes to £80.

Is any one aware of an aftermarket replacement. I cannot find an All Balls replacement at half the price, but surely KTM used the same bearing on other models.

Also, does it just hammer (sorry I mean Press!) out??


Thanks for your help.

Simon
As far as I know that bearing is a KTM special & you just have to get screwed on it if you want one. Not sure on the seals for that one but all the other lower suspension bearings & seals are definitely available at any bearing shop.

A few appropriately sized sockets & a vice makes a nice press for removal/replacement.

Quote:
Originally Posted by drdfblackm View Post
I am starting to think that an LC4 bike might be my next one...maybe. Can someone talk about ins and outs of 640 Adv vs 640E vs 625sxc.
.
If you kinda liked the DR but want something taller an LC4 would definitely be a good pick. In brief:

If you need 500km+ range, or just like the rallye look: Adv

The E is the sweet spot for me. Get one with the 18L tank.

The SXC has an extra inch of suspension which you may appreciate, but no cush hub & a smaller front brake. Small tank obviously. Some have the flat slide FCR carb which is nice vs the CV BST on the E & Adv. Most years of SXC have less oil capacity also.


The XR650L may also be worth considering - pretty basic tech like the DR but taller.

Cheers
Clint
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The wilderness, the desert - why are they not crowded
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Old 05-20-2013, 02:32 PM   #3913
Boon Booni
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Quote:
Originally Posted by Syncrosimon View Post
Hi,

I have play in the lower shock bearing on my 99 LC4 400D.

The KTM part number is

54203083050 HINGE BEARING BLASTED £45.48

And with seals and a new grease nipple it all comes to £80.

Is any one aware of an aftermarket replacement. I cannot find an All Balls replacement at half the price, but surely KTM used the same bearing on other models.

Also, does it just hammer (sorry I mean Press!) out??


Thanks for your help.

Simon
You should price a whole new pro-link. I don't think it's all that much more expensive and includes all new bearings and seals.
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Old 05-20-2013, 03:36 PM   #3914
Syncrosimon
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Quote:
Originally Posted by Boon Booni View Post
You should price a whole new pro-link. I don't think it's all that much more expensive and includes all new bearings and seals.
Thanks, I see that the whole thing is £152.00 here in the UK. Or twice just what the lower shock bearing and seals cost.

The bolts should be replaced also I guess, then it's all done.

Simon
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Old 05-25-2013, 12:09 AM   #3915
wrya1
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Simple question...?

Hello all,

A real simple question here; I've purchased a new OEM kick starter for my '02 640 ADV (turns out I was not the only one rattling my teeth out on the bike!)

The new kickstarter came with a shineee new mouth on it; but it only has half a dozen teeth on it. I looked at my old one and thought "maybe it only had a hand full of teeth too." There are marks all the way around the old one, but maybe just from where hard steel shaft was imprinting on the soft aluminium lever...

Can someone more enlightened tell me whether I have got the right kick start lever?

[IMG]New Kickstarter photo 7c568e66-7773-480f-af04-3c26c19a95b9_zpsa68bf72b.jpg[/IMG]

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