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Old 07-12-2013, 01:20 PM   #4126
mxchamp
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Joined: Mar 2005
Location: The corn state,11 curves in 318 miles (Iafalls IA)
Oddometer: 1,350
Gentlemen,

The CS seal has been replaced. Was a smashed o-ring.



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2001 KTM 640 Adventure R
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Old 07-14-2013, 09:57 AM   #4127
Sparrowhawk
Beastly Adventurer
 
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Joined: Sep 2005
Location: Eastern Washington, USA
Oddometer: 1,609
Quote:
Originally Posted by Hockeygod View Post
... it got me thinking! I am curious to hear what tools and spares you fellow 640 owners carry with you:

1. On a day / long weekend ride;

2. Extras you add for multi-day rides, say a week or two, like portions of CDT or TAT (North America)?


This is the kit I carry anytime I ride. I have assembled these tools over time with the intent of keeping it light and compact while still including everything needed for repairs short of a top end job. It handles all the normal maintenance tasks with the addition of a feeler gauge and "Creeper straw" for valve adjustments.
  • Cut off 5 mm hex key (valve covers)
  • Hex drive assortment: 1/4" square drive hex soocket, 4, 5, 6, & 8 mm hex; 8-10 flat (short & 3 1/2"), 5-6 flat, P1, P2 (short & 3 1/2")
  • CRKT mini knife
  • Sockets: 6, 8, 10, 13, & 19mm
  • 1/4" to 3/8" adapter
  • Thin wall 18mm spark plug socket (Allen brand fits the LC4)
  • 1/4" flex handle
  • 1" & 3" 1/4" drive extensions & universal
  • 5 1/2" long X 3/4" cheater (conduit)
  • Open end combination wrenches: 8/10, 10/11, 10/13, 14/17
  • KTM pliers
  • KTM axle wrench
I use a 1/4" drive because it is sufficient for anything that isn't put on wrong. I also carry: a couple of 8 1/2" tire irons, patch kit, and spare 21" tube in a fender bag for flats; a bicycle pump strapped to the top of the forks; spare clutch handle & cable; assorted cable ties; and a length of fence wire.

For multi-day trips I include a small multi-meter, electric tape, portable butane soldering iron & solder, 12 g wire, fuses, epoxy stick, chain tool, tow strap, spare shift lever, assorted nuts & bolts, spare head & tail light bulbs, and Locktite. I keep a copy of the wiring diagram on my smartphone.





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Old 07-14-2013, 02:32 PM   #4128
Young-Gun
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Joined: Dec 2005
Location: Brisbane, AUS
Oddometer: 574
Quote:
Originally Posted by dolphins13 View Post
I have a 99 lc4e 640. Has been a perfect bike till now. (3500 miles ive owned it) The last 3 times I rode it to the gym. It dies on my way home and dosnt sart till i truck it home then it starts? Seems like I get a carb full of gas away from gym? Floats maybe? The tilting of the bike to load and unload has to be playing a part? I tried taking gas cap off in case it was vapor lock. If a main jet got plugged it wouldnt keep unplugging? Hoping for good advice before I start tearing it apart. My carb is a real pia to take out. Hoping I can adjust floats with carb still on? It has spark. Bike has run flawless till now.
Try going to a different gym?
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Old 07-14-2013, 03:25 PM   #4129
TexasDirt
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Joined: Jun 2012
Location: Houston, TX
Oddometer: 12
Quote:
Originally Posted by dolphins13 View Post
I have a 99 lc4e 640. Has been a perfect bike till now. (3500 miles ive owned it) The last 3 times I rode it to the gym. It dies on my way home and dosnt sart till i truck it home then it starts? Seems like I get a carb full of gas away from gym? Floats maybe? The tilting of the bike to load and unload has to be playing a part? I tried taking gas cap off in case it was vapor lock. If a main jet got plugged it wouldnt keep unplugging? Hoping for good advice before I start tearing it apart. My carb is a real pia to take out. Hoping I can adjust floats with carb still on? It has spark. Bike has run flawless till now.
I had similiar symptoms recently. I rejetted, cleaned the carb, opened my air box, you name it!
Ended up being a frayed wire that would depending on how my arse was positioned on the seat, make connection or lose connection! Things are not always what they seem. My carb was fine but now I have much more HP!!
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Old 07-14-2013, 09:39 PM   #4130
bmwktmbill
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Joined: Jul 2005
Location: Traveler
Oddometer: 4,570
Quote:
Originally Posted by dolphins13 View Post
I have a 99 lc4e 640. Has been a perfect bike till now. (3500 miles ive owned it) The last 3 times I rode it to the gym. It dies on my way home and dosnt sart till i truck it home then it starts? Seems like I get a carb full of gas away from gym? Floats maybe? The tilting of the bike to load and unload has to be playing a part? I tried taking gas cap off in case it was vapor lock. If a main jet got plugged it wouldnt keep unplugging? Hoping for good advice before I start tearing it apart. My carb is a real pia to take out. Hoping I can adjust floats with carb still on? It has spark. Bike has run flawless till now.
There is a small screen in the fuel inlet pipe that could be partially plugged.You could try checking that before ripping the carb off.
bill
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The faster it goes the faster it breaks.
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Old 07-14-2013, 11:26 PM   #4131
dnrobertson
Big Bike, Slow Rider
 
Joined: Jun 2008
Location: Frankston, Australia
Oddometer: 653
Quote:
Originally Posted by bmwktmbill View Post
There is a small screen in the fuel inlet pipe that could be partially plugged.You could try checking that before ripping the carb off.
bill
Along those lines, how about the filter on the actual fuel tap in the tank. Take the hose off the fuel tap and see how much flow you are getting there?
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Old 07-15-2013, 02:53 PM   #4132
clintnz
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Joined: May 2004
Location: Rotoiti, New Zealand
Oddometer: 3,056
Kinked fuel line is another one to check for before pulling the carb.

Cheers
Clint
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Old 07-15-2013, 03:10 PM   #4133
rtwpaul
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Joined: Feb 2011
Location: in a holding pattern
Oddometer: 1,394
Quote:
Originally Posted by Hockeygod View Post
Thanks for your input on the tools and spares!

Next Q: Did your 640 come with the tool carrier under the side panel? Mine (2007) didn't; I was hoping I could get the dimensions so maybe I could fab one. Measurements, pic would be great if possible. This will create tool and spare space so I can redistribute things...

Or if someone could point me to a website where these (or something similar) are sold, it would be appreciated.

Thanks,

Dean
PM me if you want one, took mine off and won't be needing it anymore, just pay the shipping and its yours
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Old 07-15-2013, 05:16 PM   #4134
dolphins13
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Joined: Jan 2012
Location: spo wa
Oddometer: 144
Hard to fix a problem that fixes itself? When it dies on me, then I mess

with it on the side of the road hoping it will start again. It dosnt start so I

truck it home. Wont start in truck either. When I get home it fires up and

I cant fix what aint broke. Three times in a row this has happened. After

the 1st time I bravely took it for a 10 mile or so ride and it was perfect.

next week it dies when I leave the gym again? and a week later does the exact

same thig. Right now it starts and runs great, trick is to get it broke

down at home? How does the ride home in truck fix it? Im really stumped

on this one? gonna wear out my kickstarter or kill my battery on the side

of the road if this continues. Its what I get for bragging how my bike

always runs perfect? It used to.
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Old 07-15-2013, 06:01 PM   #4135
Boon Booni
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Joined: Aug 2003
Location: Richmond, Va
Oddometer: 12,556
Quote:
Originally Posted by dolphins13 View Post
Hard to fix a problem that fixes itself? When it dies on me, then I mess

with it on the side of the road hoping it will start again. It dosnt start so I

truck it home. Wont start in truck either. When I get home it fires up and

I cant fix what aint broke. Three times in a row this has happened. After

the 1st time I bravely took it for a 10 mile or so ride and it was perfect.

next week it dies when I leave the gym again? and a week later does the exact

same thig. Right now it starts and runs great, trick is to get it broke

down at home? How does the ride home in truck fix it? Im really stumped

on this one? gonna wear out my kickstarter or kill my battery on the side

of the road if this continues. Its what I get for bragging how my bike

always runs perfect? It used to.
You're going to have to figure out a way to check spark next time it happens. Need to whittle the problem down to electrical or fuel related.
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Old 07-15-2013, 08:45 PM   #4136
ChrisC
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Joined: Feb 2003
Location: Prescott, Arizona USA Earth
Oddometer: 6,302
Make sure the fuel tank is properly vented to atmosphere...
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Old 07-15-2013, 09:33 PM   #4137
overlandr
Temporal Shifter
 
Joined: Nov 2003
Location: Sydney
Oddometer: 5,775
Hey Dolphins13, what have you done to address the wiring harness/loom? Your bike is older so there's a good chance that there is some wear on the insulation.
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Old 07-15-2013, 09:51 PM   #4138
Beta450
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Joined: Nov 2010
Oddometer: 41
Carry a can of starting fluid and if the bike acts up again spray some iin the air box and if it fires up then it's a fuel problem. If it does'nt then it is a electrical problem.
It's just a quick method that I use to help find a problem.
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Old 07-16-2013, 11:45 AM   #4139
DolphinJohn
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Joined: Mar 2007
Location: Key West-Island of Misfit Toys
Oddometer: 3,645
My cock was leaking

2000 640 Enduro with the 18 liter tank. I had replaced it (fuel cock) a couple of years ago for the same reason.

I just had the tank off, drained and cleaned (for another issue) and got everything back together and the damn thing would not stop dripping in the "on" and reserve positions.

I took it apart several times and the o-ring looked good. If I put pressure upwards on the dial it would stop.

Finally I tried taking the little spring out and it is now dry as a bone. Doesn't seem to be any problem not having it in there, other than a lack of feeling the notch at the "off" position.

Just FYI if anyone has the same issue.

.
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Old 07-16-2013, 12:44 PM   #4140
Nokmuay
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Joined: Aug 2007
Location: South Western Ontario, Canada
Oddometer: 512
hey Guys!!!
just curious. What are you all using for sproket set up? I had purchased this 2005 640 adv and replaced the wearing sprokets with stock, but noticing its top end isnt as nice. But its a little nicer in the dirt and tough hills. Just curious, if the consensus is to stick with the stock ratio or change em up? Also same ? for carbs. Are people sticking with the stock carb or upgrading? Thanks. Trying to get the most out of this machine.

Also Is there anyone withing a few hours of Either Detroit Michigan, or Kitchener / or / Toronto Ontario thatas a good wrench on these? id like to get an overall refresh and see where it is, as Im not 100% how much the preivious owner(s) did with it. Figured if I can find a good wrench at a fair price, would be beneficial to us both, and I could learn a little maybe.
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