Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > KTM Tech

KTM Tech KTM Tech Forum - For Questions specific and of interest to KTM riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 25 Jul 2005
Registered Users
Veteran HUBBer
Join Date: Sep 2002
Location: Tomahawk,Wisconsin
Posts: 220
640 Adventure changes

Hi Everyone,
Just purchased a 2002 640 Adventure after a sixteen month ride from the Arctic Circle to Tierra del Fuego on my 1983 BMW R80ST-G/S. I wanted a newer, lighter bike. The 640 isnt perfect and the seat height , lack of hard luggage and engine/wheel reliability top the list of noted complaints. What,s the fix. Can the LC 640 be made into a travel bike to live with for the long haul.
Thanks. Bill.
Reply With Quote
Old 25 Jul 2005
Registered Users
HUBB regular
Join Date: Mar 2005
Location: Flagstaff,AZ U.S.A.
Posts: 81
The 640 series makes a great travel bike,but all is not perfect.I use a sheepskin cover on the stock seat.you can buy the comfort seat from KTM,or consider the Airhawk seat cushion.Hard luggage is available from Touratech,Happy-Trail,Hepco and Becker,Darrs,Off-The-Road,Jesse,and several other brands.I use the Zega/touratech setup.The engine is reliable,although labor intensive to maintain.Overall the 640's can take a beating.There is a wealth of info available,including: use,modifications,problems,ect.in this forum.
Reply With Quote
Old 25 Jul 2005
Registered Users
HUBB regular
Join Date: Nov 2003
Location: Sydney, Australia
Posts: 57
Contact Jerome on this forum - he is your best resource on this MC

[This message has been edited by overlandr (edited 25 July 2005).]
Reply With Quote
Old 26 Jul 2005
Registered Users
HUBB regular
Join Date: Nov 2002
Posts: 60

For travelling I did the following mods...
- put in a 2nd radiator fan on the right side radiator as I was expecting to do a lot of work in soft sand.
- lowering links to drop the seat hight a couple of centimetres (mine is a 1999 which is even higher on the seat). My wife had some of the foam scalloped out of her seat.
- large inline fuel filter (didn't need changing over 30,000km
- steel (stealth) rear sprocket (I opted for a 45 tooth rear to give me more torque in soft sand) with X-ring DID chain. Lasted full trip (London -> Cape Town)
- touratech pannier & rack
- switchable CDI to cope with low octane fuel (with dash mounted switch)
- combo side stand & main stand
- light weight exhaust
- ali tool box bolted to bash plate (carefull what you put in here - lot of vibration and corrosion)

Bike was great and 100% reliable with exception of front fork seals which both needed replacing (I used automatic transission fluid instead in place of fork oil which I couldn't find at the time - similar viscosity).

Here are a few www's you may find usefull ...

http://www.ktmtalk.com/ is a good forum for technical queries with KTM's

Also check out http://www.ktminfo.com/ktm.asp for the full parts list (much easier to order the correct part if you can quote the part number rather than relying on descriptions)

You can find a lot of bolt on type extras for your KTM at http://www.touratech.de and http://www.ktm-sommer.de/Seiten_05/f_start_05.html

[This message has been edited by tifua (edited 25 July 2005).]
Reply With Quote
Old 26 Jul 2005
Ian Ian is offline
Contributing Member
Veteran HUBBer
Join Date: Aug 2000
Location: UK
Posts: 427
Hi Bill,

I think I replied to your post on advrider.com. To my knowledge there aren't many issues - I have a 2002 640LC4-E and have had the mainshaft bearing replaced. There's loads on this on advrider and ktmtalk.

I've recently had a problem with the drive sprocket. I'll be posting on this soon, but it comes down to using the correct screw, loctite and correct torque.

Then there's the recall described elsewhere on this forum for the front wheel spokes.

The seat pre-2003 was in my opinion painful after just a relatively short distance - I'm sure owners would agree. Be careful - the 'comfort seat' from KTM's power parts list, at least in the UK, is for the LC4-E, not the Adventure. The tank on the E is a different shape to the adventure where the seat fits. But the seat on the 2004 (and possibly 2003) Adventure onwards is apparently much better and should fit your 2002.

I always fit steel or the 'stealth' type of rear sprocket. Add a headlight guard, a lightweight silencer and a luggage system and IMHO the Adventure's ready to go. If you have a look around the web there's loads of other accessories for the Adventure. One vendor from whom I've received good service is Sommer in Germany (www.ktm-sommer.de).

I'm currently researching a new baggage system for my bike. Again I'll post when I've bought and tested.


Reply With Quote
Old 27 Jul 2005
Gold Member
Veteran HUBBer
Join Date: May 2001
Location: Manchester, UK
Posts: 381
Seat for the 2003 Adventure seems fine to me, I've just come back from 4000 miles in 19 days.....

Having said that I'm not used to a BMW!!!!!

Reply With Quote
Old 29 Jul 2005
Registered Users
Veteran HUBBer
Join Date: Oct 2004
Location: London
Posts: 545
Agree with most of the suggestions.

Definately fit a second radiatior fan on the right side for any riding in the desert.

Headlamp guards can be made cheaply with small pieces of perspex held on with double sided taped. Mine have lasted 20,000 + kms on dodgy African roads - no need for the expensive option from KTM Sommer.

Steel rear sprocket is an absolute must. Even with steel, I have beem wearing my rear sprocket after 8,000kms.

I prefer soft panniers, as they leave the bike a lot lighter and more dropable. Theft is rarely a problem on overland bikes, and I have been happy to leave my stuff completely unlocked in villages everywehere, although take precautions in the cities. My one luggage suggestion would be to take a waterproof kayaking duffle as your rear bag.

Sheepskin cover is useful for comfort, and also makes it bearable riding in hot conditions in shorts, when the standard seat can heat up from the sun.
Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

Next HU Eventscalendar

See all events


Latvia to Australia, an inspirational 5 month journey full of unexpected adventures!

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 00:46.