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Contact Overland Solutions for all your custom modifications and setup for overland travel.

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  #1  
Old 25 Jul 2005
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Location: Tomahawk,Wisconsin
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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.
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  #2  
Old 25 Jul 2005
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Location: Flagstaff,AZ U.S.A.
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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.
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  #3  
Old 25 Jul 2005
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Contact Jerome on this forum - he is your best resource on this MC

[This message has been edited by overlandr (edited 25 July 2005).]
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  #4  
Old 26 Jul 2005
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Hi

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).]
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  #5  
Old 26 Jul 2005
Ian Ian is offline
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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.

Cheers,

Ian.
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  #6  
Old 27 Jul 2005
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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!!!!!

Dave
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  #7  
Old 29 Jul 2005
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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.
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