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Old 05-29-2014, 11:26 AM   #1
Petterabborre OP
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Trouble starting 640 Adventure

Im trying to get my fathers 640 Adventure 2003 to start, but no success after trying for a few months. Is hasn't been used for about 2 years.

* New spark plug
* New gasoline
* Ultrasonic cleaned carb
* Taken apart and cleaned starter engine
* New battery

It has been started with starter fluid and kickstart but is very hard to start. Even with fully charged new battery the engine starter won't really turn, some relay is just clicking.

Im running out of ideas to get it to start..
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Old 05-29-2014, 12:09 PM   #2
Black Hills
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new battery will most likely solve the problem.
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Old 05-29-2014, 12:35 PM   #3
Mikef5000
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Try jump starting it from a car (that isn't currently running). If that works, then it's your battery. (Even though it's new, doesn't mean it's good).

Also, this post should be in the Thumpers section, not the Orange Crush (KTM Twins) section.

Good luck!
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Old 05-29-2014, 12:37 PM   #4
steveWFL
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valve lash check done recently?
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Old 05-29-2014, 12:51 PM   #5
Mr Head
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You state: "... it has been started..." Using starter fluid.
This leads me to ask how the carb was cleaned, ultrasonically? Taken completely apart?
As in all jets removed?
Or minimal quickie clean.
I suspect the low speed circuit / idle is clogged.
Everything that burned gas I ever revived had the low speed circuit clogged up. It is the smallest orifices in carb and hardest to clean.
That is my guess for that part.
The clicking relay has to be the starter relay. Check the contacts there back thru the battery.

Good luck.
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Old 05-29-2014, 01:31 PM   #6
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^ this
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Old 05-30-2014, 12:57 PM   #7
Petterabborre OP
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Sorry about putting this in the wrong section - first post. Maybe a mod can put it where it belongs?

It has a completely new battery so nothing wrong with the battery. I have tried hooking it up with a car battery, it cranks a few times more than with the original batteri but it won't fire, and then the jumper cables begins to smoke..

The carb were completely disassembled and cleaned ultrasonically. How should the idle screw and and airscrew (if that is the screw near the float bowl on the left side?) be set?
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Old 05-30-2014, 01:26 PM   #8
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The idle mixture screw in my experiences have usually ended up 1-1/2 turns to 3 turns out from seated. I'd count the turns to lightly seated and turn it back out two or so as a start. It is extremely difficult to clean the tiny passage in the carb for the low speed circuit.

Smoking the jumper cable is something else. I've never seen that. IF the motor won't fire, I'd first check that there was spark from the CDI. If not that is bad.



Quote:
Originally Posted by Petterabborre View Post
Sorry about putting this in the wrong section - first post. Maybe a mod can put it where it belongs?

It has a completely new battery so nothing wrong with the battery. I have tried hooking it up with a car battery, it cranks a few times more than with the original batteri but it won't fire, and then the jumper cables begins to smoke..

The carb were completely disassembled and cleaned ultrasonically. How should the idle screw and and airscrew (if that is the screw near the float bowl on the left side?) be set?
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Old 06-01-2014, 03:56 AM   #9
Alik
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The jumper cables begin to smoke makes me wonder - looks kinda electrical problem to me.
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Old 06-01-2014, 06:00 AM   #10
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Quote:
Originally Posted by Alik View Post
The jumper cables begin to smoke makes me wonder - looks kinda electrical problem to me.
my 640 LC4 enduro does this if I put a jump pack on it. the starter wont turn it over properly, it kind of half turns and stops, although all appears good inside, and putting a feed straight onto the connection (ie bypassing starter relay etc) doesnt change anything.

I think I either have a duff motor, or maybe the auto decompression thingie isnt working, although pulling the manual one (which does work) doesn't alter anything with the starter fault either.

happily mine goes on the kick starter easily enough, (after the previous owner showed me the 2 cycle decompression routine and how to do it right) as KTM quoted 370 Euros ($500) for a new starter.
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Old 06-02-2014, 01:26 AM   #11
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Take the starter off and disassemble/clean it or take it to and electrical tech for evaluation.

b
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Old 06-02-2014, 01:43 PM   #12
Petterabborre OP
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The starter has been disassembled and cleaned, and works good when tried outside of the motor.

I have changed the slip-on from a LeoVince to original, can that have something to do with it?
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Old 06-02-2014, 02:35 PM   #13
bisbonian
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Have you tried pulling in the decompression lever when starting?

Perhaps your auto decompression isn't working correctly, too much compression is bogging the starter.
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Old 06-02-2014, 02:46 PM   #14
Mr Head
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http://www.advrider.com/forums/showthread.php?t=670733

Maybe here:
LC4 Manual


Quote:
Originally Posted by bisbonian View Post
Have you tried pulling in the decompression lever when starting?

Perhaps your auto decompression isn't working correctly, too much compression is bogging the starter.
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Mr Head screwed with this post 06-02-2014 at 02:53 PM
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Old 06-03-2014, 07:08 AM   #15
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Quote:
Originally Posted by bisbonian View Post
Have you tried pulling in the decompression lever when starting?

Perhaps your auto decompression isn't working correctly, too much compression is bogging the starter.
With a fully charged battery the engine turns when Im pulling the decompression lever, but when I let the lever go the engine stops turning. Maybe time to check the auto decomp?
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