Up-to-date: KTM 640 LC4 Adventure changes between model years

[LukasM]

Hi guys,

Since I am looking at buying an LC4 Adventure again, I did a bunch of searches here and on other forums what parts exactely changed over the years. I found tons of info and many long threads (with too much BS in between). So I started compiling the info in one up to date place.

Feel free to make suggestions for changes or add some new info, I will update the first post in the thread to keep it current.

Cheers,
Lukas

1997
620EGS-E Adventure
All orange
609cc, low-slung twin silencers, Dell Orto Carburettor
WP 50mm Extreme forks
17mm front axle

1998
Changed to 640LC4 Adventure R
Orange and blue
625cc, high level pipe
main stand

2000
Slightly different colour scheme (all blue seat, tank graphics 'reversed') Mikuni Carb
Rims pre-drilled for locks
Dual odometers

2001
New colour scheme (orange back, silver front)
Opaque screen with flip was discarded in favour of solid colour, lower non-flip screen
Adopted rear subframe/panels/fenders from 640LC4-E, new opaque screen
USD 48mm front forks, front brake disc 320 mm (vs. 300)

2002
Slightly different colour scheme (the 'KTM' on the tank became black)
New type of tripmaster incorporating coolant temperature and fuel 'low' warning (instead of Touratech IMO)
Frame has a cast lug rather than a flattened tube on the lower right engine cradle to accommodate the easier access to the oil filter
Fuel pump was moved to the area behind the cylinder

2003
New colour scheme silver and black
'High flow' cylinder head with 32mm exhaust valves vs. 30mm, dual curve CDI, new cam, hydraulic clutch, oil level window in primary drive cover, input shaft bearing changed from ball to roller, bigger oil filler screw on frame, oil pump drive ratios increased
Slightly different fuel plumbing, 40BST carb fitted with a TPS
Secondary air system (SAS or SLS) for "Euro 2" emmissons standard introduced to EU bikes
Different primary drive gearing (changed from 30:81 to 31:79)
Location of merge collector and elimination of separate cross-over, exhaust pipe (still high level)
Location of fuses moved to battery tray area, 10A un-switched powerlet plug in dash
More comfortable seat
Assist tab added to center stand, structural change in swingarm "arms" and chain adjuster blocks,

2004
New orange colour scheme
Low front fender
Same front suspension as 950 Adv with twin front discs, foot brake pedal wider and fold-away, wider footpegs with new rubber inserts, Front left footrest bracket made from aluminum
Black wheel rims (no longer pre-drilled for locks)
Locking fuel cap, fuel tank capacity is quoted as 25.5L rather than the 28L for the earlier models
SAS/SLS for US spec bikes
Reinforced outer clutch hub, CDI with optimised ignition curve, changed the auto decomp components but not design

2005
New oil feed line to base of piston
Smaller indicators
15mm handlebar risers
Sintered brake pads, a new Brembo brake disc with round holes
X-ring endless chain

2006
Canadian model has no SAS/SLS
Behr rims improved (do not bend as easily but still not as good as Excel)
Black powdercoated frame

[christian]

Love it,. I am also looking... very instructive.

[meat popsicle]

Austria uber alles. The Index needs a one-stop post for this kind of info, danke Lukas.

I will look over it later, but I am not the best at model year changes.

[SPEd600]

Two other versions were also offered in 97:
1997 620 R / XCe (Electric Starter)
1997 400 R / XCe (Electric Starter)
I test rode a 620 in 96 (no electric) ... had to drive to Michigan though.

1997 620 EGS - E Adventure was called an LC4... I still have the original brochure.

"Innovatave features like side mounted extra fuel tank and spare tire carrier are all over the LC4 Adventure."

[LukasM]

Originally Posted by meat popsicle

Austria uber alles. The Index needs a one-stop post for this kind of info, danke Lukas.

I will look over it later, but I am not the best at model year changes.

The GENIUS index thread is were I got most of the info from, so kudos go to you

Originally Posted by SPEd600

Two other versions were also offered in 97:
1997 620 R / XCe (Electric Starter)
1997 400 R / XCe (Electric Starter)
I test rode a 620 in 96 (no electric) ... had to drive to Michigan though.

1997 620 EGS - E Adventure was called an LC4... I still have the original brochure.

"Innovatave features like side mounted extra fuel tank and spare tire carrier are all over the LC4 Adventure."

Were the other two also adventure models (large tank, fairing etc)?

[meat popsicle]

been a few questions along these lines, and this ain't in the index, yet.

[Loadedagain]

Originally Posted by meat popsicle

been a few questions along these lines, and this ain't in the index, yet.

get on it man...

[meat popsicle]

Originally Posted by Loadedagain

get on it man...

I tried, but Post #1 is over 30,000 characters again, so I need to cull more "optional stuff" down to Post #2, which is reaching 30K to as I recall; might need to dump a bunch of crap.

I need a block of time to do that, and a reorganization idea of mine... check's in the mail.

[LukasM]

I am on standby too if anybody has more or different info....

My Canadian delivered 06 had no SAS system. Blanking plate between exhaust header where SAS would inject.

The Behr rims seem to be better for 06 as well. Still too wide on the front but less prone to bending. I've had 3 pinch flats and no bent rim which sounds a whole lot better than others have experienced.

Blair

[LukasM]

Originally Posted by Surlyguy

My Canadian delivered 06 had no SAS system. Blanking plate between exhaust header where SAS would inject.

The Behr rims seem to be better for 06 as well. Still too wide on the front but less prone to bending. I've had 3 pinch flats and no bent rim which sounds a whole lot better than others have experienced.

Blair

Do you know if the 04 and 05s had the SAS in Canada? They probably didn't get less strict regarding emissions, so it would make sense if they never had it.

For the Behr rims, I couldnt find anything official if they had changed them. Let me know if somebody knows more!

Don't know if the 04 and 05's had the SAS. Will try to find out but they are pretty rare around these parts.

The Canadian rep told me on the phone that the Behr rims were fixed for 06 for what it's worth. He also told me when I bought the bike that the rims would be D.I.D. for 06 to put the information in perspective.

Originally Posted by LukasM

Do you know if the 04 and 05s had the SAS in Canada? They probably didn't get less strict regarding emissions, so it would make sense if they never had it.

For the Behr rims, I couldnt find anything official if they had changed them. Let me know if somebody knows more!

[Jan from Finland]

My model 2000 has dual odometers in IMO (2001) and pre-drilled rims (2002).

Are you sure about the different tranny gearing in 2003? I thought that the difference is roller bearings instead of ball bearings.

[ChrisC]

Originally Posted by Jan from Finland

My model 2000 has dual odometers in IMO (2001) and pre-drilled rims (2002).

Are you sure about the different tranny gearing in 2003? I thought that the difference is roller bearings instead of ball bearings.

By "tranny" I think we're talking primary drive gearing. My '03 primary ratio is 31:79, not sure on the earlier LC4. The ball to roller input shaft change was also 2002-2003.

[fasteddy]

Originally Posted by LukasM

Do you know if the 04 and 05s had the SAS in Canada? They probably didn't get less strict regarding emissions, so it would make sense if they never had it.

For the Behr rims, I couldnt find anything official if they had changed them. Let me know if somebody knows more!

I've had the 03, the 05 and currently ride the 06 version. The 05 had the SAS, the 04 was not brought into Canada! I was surprised to see it (the SAS) gone on the 06 when I took delivery, I also was told that the 06 rims had been strengthened, the rims do seem stronger in 06, still-- I bent the crap out of the front and am looking to upgrade to a set of excels from Woody's Wheels.

Hope this helps.


Ed...