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Old 06-20-2013, 01:00 PM   #91
NSFW
ktm's "the tourist"
 
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Joined: Feb 2007
Location: Burbank CA
Oddometer: 15,713
shameless plug........




rr over here


i love my 640e! it has taken to a lot of places and never let me down.
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Old 01-21-2014, 05:01 PM   #92
kyalbert
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Joined: Jan 2014
Oddometer: 10
2000 640 lc4-e

I was just gifted a 2000 640 LC4-E - along with it's entire service history. This bike has 10k miles on it. Looks absolutely brand new. It is completely unmodified. An old friend put mostly highway miles on the bike, and parked it 5 years ago. He said it was making an engine noise he didn't like when he parked it and replaced it with a BMW GS1200. While the KTM was still under extended warranty, he had it in to the local KTM dealer twice to look at it. After scouring the paperwork he had, sure enough, I see a note from the dealer stating "this sound is the decrompressor, it is normal". Over the weekend I went through the gas tank, carb, and fuel lines, cleaning or replacing rubber as needed. Also charged up the battery. I put my trusty electric heater under the motor and let it warm up over night (unsticks the gummy stuff you know) and yesterday I fired her off. This bike purrs like a kitten, runs like a raped ape, and when warmed up at idle, here comes that awful noise. In my 40 years of mechanical experience, it sounds like there is a bolt bouncing around in the valvetrain - very intermittent. I've been sifting through lots of threads here, and all over the web on this problem. Next thing is to adjust the idle speed - I'm thinking it may just be idling low and when it dips to a certain speed the decomp kicks in. Opinions?
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Old 01-21-2014, 05:54 PM   #93
gunnerbuck
Island Hopper
 
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Joined: Nov 2005
Location: N.V.I, B.C.
Oddometer: 3,707
Quote:
Originally Posted by kyalbert View Post
I was just gifted a 2000 640 LC4-E - along with it's entire service history. This bike has 10k miles on it. Looks absolutely brand new. It is completely unmodified. An old friend put mostly highway miles on the bike, and parked it 5 years ago. He said it was making an engine noise he didn't like when he parked it and replaced it with a BMW GS1200. While the KTM was still under extended warranty, he had it in to the local KTM dealer twice to look at it. After scouring the paperwork he had, sure enough, I see a note from the dealer stating "this sound is the decrompressor, it is normal". Over the weekend I went through the gas tank, carb, and fuel lines, cleaning or replacing rubber as needed. Also charged up the battery. I put my trusty electric heater under the motor and let it warm up over night (unsticks the gummy stuff you know) and yesterday I fired her off. This bike purrs like a kitten, runs like a raped ape, and when warmed up at idle, here comes that awful noise. In my 40 years of mechanical experience, it sounds like there is a bolt bouncing around in the valvetrain - very intermittent. I've been sifting through lots of threads here, and all over the web on this problem. Next thing is to adjust the idle speed - I'm thinking it may just be idling low and when it dips to a certain speed the decomp kicks in. Opinions?
If your idle is set much below 1500 rpm the auto decomp will produce the klak klak intermittently... Most 640s have a happy idle around 1600 rpm....
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Old 01-21-2014, 08:03 PM   #94
kyalbert
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Thanks Gunnerbuck - here's a youtube video of the bike running. You can hear the clack clack right of the bat. It does appear to be idle speed related. Anytime it drops below a certain rpm is where it occurs. I'll have to borrow a tachometer from my neighbor and see where it's sitting. https://www.youtube.com/watch?v=jLeXUPvm548
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Old 01-21-2014, 08:06 PM   #95
kyalbert
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youtube bideo of the 640 running

Here's a youtube video of the 640 and what I believe is the decompressor noise. Is there an opportunity for damage to occur here? Is this idle set too low in your opinion?
https://www.youtube.com/watch?v=jLeXUPvm548
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Old 01-21-2014, 08:09 PM   #96
Geekventure
Ronzoni
 
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Joined: Sep 2005
Location: San Francisco
Oddometer: 82
Roller Bearing Check...

There's also the worst case scenario...

Quote:
Originally Posted by Geekventure View Post

It could also be the roller bearing on it's way to complete destruction!




I have this exact bike...and it happened to me...first were the strange noises coming from the engine, until eventually I could not get it out of gear and thankfully was able to limp the F^@& home...

NOTICE MY OLD 620'S BLOCK HAS A CRACK IN IT TO THE LEFT OF THE BEARING!



I ended up just replacing the whole motor with one out of a 2001 super moto. Unfortunately, it has no electric starter hookup.

QUESTION:

Does anyone know if I can use my e-starter hookup/motor from the old 1997/8 620 motor and attach it to my current 2001 640 e-starter-less motor?
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2002 640 LC 4-E ROT 18L USA
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Old 06-30-2014, 08:29 PM   #97
Goomicoo
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Joined: Nov 2010
Location: Here & There
Oddometer: 546
Buggered wires under the seat of a 2002 KTM 640 LC4E

I picked this bike up yesterday. It wouldn't turn over but the main fuse was the culprit there. It turns over but doesn't fire. I found these exposed wires under the seat so I figured they have something to do with it. I don't have a wiring diagram so here I am with my puzzle.
The group of wires going to the white plug for the relay have these issues.
Orange one has no home!
Brown wire with the male bullet connector connects to one of the black wires for the side stand switch. ( For reference the 2 black wires were twisted together down at the side stand in what I imagine was done to bypass the side stand)
In the second picture you see another wire loom where 2 black wires coming from what I imagine to be a diode don't have a home either!
Did they both connect to the other black wire that goes down to the side stand? I'm lost without a wiring diagram so if someone has a pic of their setup that would be great. Or tell me where to find a diagram. All I could find is an adventure diagram and it doesn't seem to jive. Thanks in advance.




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Started with a Honda 400/4, then a RD400, then...
R65, R1100S, R1100RT, R1150R X 2 , R1150GS, R1150GSA, R90/6, R60/5, R80/7 X 2, R60/2, R50/2, R69s X 3, KTM 625 smc, 525 exc, LC4 640, Duke II,
640 Adv.
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