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Old 04-29-2005, 12:27 PM   #1
FlyinGo!!!!! OP
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Eh? What's the difference:2002,3,4 Ktm640 adv

Can anyone tell me the differences between the 2002-3-4 years of the KTM 640 Adventure?
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Old 05-02-2005, 12:27 PM   #2
Velocibiker
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Quote:
Originally Posted by FlyinGo!!!!!
Can anyone tell me the differences between the 2002-3-4 years of the KTM 640 Adventure?
2-3

hiflo head
hydro clutch
assist tab added to center stand
different valves/cam? (not sure)
different seat
power outlet in dash

what else?

3-4

Not sure as '04 was not available in the US


3-5

front end suspension & brakes same as those on the 950.

what else?
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Old 05-02-2005, 12:58 PM   #3
Mack
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http://www.ADVRider.com/forums/showthread.php?t=76968
Quote:
Originally Posted by Mack
The development of the model year 2004 is mainly characterised by new detail solutions and several technical modifications.

Front left footrest bracket made from aluminum.
Wider footrests.
New rubber inserts for front footrests.
Foot brake wider and folds-away.
New secondary air system (SLS) is more compact and complies with emission standard “Euro II”.
CDI with newly optimised ignition curve.
Newer, reinforced outer clutch hub ensures better and safer gear shifting under the most difficult offroad conditions.
New decals.
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Old 05-02-2005, 01:32 PM   #4
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Quote:
Originally Posted by Velocibiker
2-3

hiflo head
hydro clutch
assist tab added to center stand
different valves/cam? (not sure)
different seat
power outlet in dash

what else?
2003 As stated by Velo and... to my knowledge:

cam (timing change unknown)
valves (32mm vs. 30mm exhaust valves... not retrofitable. Must retro entire "high-flow" head)
ignition map (again, change unknown)
exhust system diameter, location of merge collector and elimination of separate cross-over.
oil pump drive ratios incresed
location of fuses moved to battery tray area.
structural change in swingarm "arms" and chain adjuster blocks.

That's all I got off the top of my head,
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Old 05-02-2005, 02:24 PM   #5
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2002 is the best.
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Old 05-02-2005, 02:36 PM   #6
gaspipe
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Couple other things not yet mentioned in the +'03 bikes:

1) different dashboard panel, IMO and tach
2) different tranny gearing (I think the primary ratio was different)
3) slightly different fuel plumbing
4) 40BST carby fitted with a TPS (to tell that revised CDI box what to do)
5) oil sightglass replaced dipstick in new sidecover castings
6) revised mainshaft bearing

Can't think of anything else off the top of my head. Work sux.
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Old 05-02-2005, 04:29 PM   #7
Stephen
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And isn't it true that in 03 the bottom frame rail was modified (i.e, bent ) to make it easier to renew the oil filter?
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Old 05-02-2005, 05:18 PM   #8
FlyinGo!!!!! OP
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Thumb Thanks

Thanks for all the input. I have a client looking to buy soon and trying to decide between the 640 and the 950 and he is looking for used, so learning any differences is very helpful to him. Thanks! I now return to myself to "Orange Crush".
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Old 05-02-2005, 06:38 PM   #9
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Quote:
Originally Posted by Stephen
And isn't it true that in 03 the bottom frame rail was modified (i.e, bent ) to make it easier to renew the oil filter?
That change occured in the mid '02 model year... as far as we can tell.
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Old 05-02-2005, 06:44 PM   #10
Surly
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Quote:
Originally Posted by Loadedagain
2002 is the best.
As long as your wearing a dress and pointing a shotgun at me I will agree

Otherwise you are off a few years!...and I think you know how many
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Old 05-02-2005, 07:20 PM   #11
daotoys1
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The bottom frame craddle mod to allow easy access to the oil filter is a 2002 change....my 2002 KTM LC4 640 AdventureR has this update...
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Old 05-03-2005, 01:46 AM   #12
Nom de Guerre
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Quote:
Originally Posted by Loadedagain
2002 is the best.
Dress or no dress, Mr. Loaded is correct. Sorry for the rest o' you suckers. It is well known among the LC4 aficionados that KTM is struggling to find the magic they achieved in the near perfect '02 model (perfect once you've done the bearing swap)

Oh yeah, doesn't the '05 (may have started in '04) have an added oil injector under or by the piston?
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Old 05-03-2005, 05:00 AM   #13
The Misinformant
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03-04
Apart from colours and the front end. They changed the auto decomp components but not design from 03 to 04. 03 build bikes had auto decomp problem were it was slipping below about 3000 RPM. They started to fault from around 4000 kms. All were fixed under warranty and the new upgraded part numbers matched the 04 part numbers for camshaft and decomp parts.

Rest pretty much the same mechanically.
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Old 05-03-2005, 06:34 AM   #14
meat popsicle
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Quote:
Originally Posted by The Misinformant
03-04
Apart from colours and the front end. They changed the auto decomp components but not design from 03 to 04. 03 build bikes had auto decomp problem were it was slipping below about 3000 RPM. They started to fault from around 4000 kms. All were fixed under warranty and the new upgraded part numbers matched the 04 part numbers for camshaft and decomp parts.

Rest pretty much the same mechanically.
hm, this is new info - got a service bulletin number on that?
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Old 05-03-2005, 06:54 AM   #15
ChrisC
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Quote:
Originally Posted by LC4 Pilot
It is well known among the LC4 aficionados that KTM is struggling to find the magic they achieved in the near perfect '02 model
Would that be the '02 model with the Lo-Flow head and the funny paint scheme?
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