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  #1  
Old 7 Apr 2005
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640 Adventure - Which Year ?

Hi, Can you Guys tell me all the improvements/changes made to the Adventure 640 over the years and some input on which model year to go for - I need reliability - The bike will be doing commuting over the summer and a West Africa trip next winter.
So Is it worth getting an earlier model and doing some upgrades ? or best to save some more and go for a 2003 or later model ?
Any Info Greatly Appreciated
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Grif
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  #2  
Old 8 Apr 2005
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Difficult question, as a used 1997 might be in better condition than a 2004....

For me best one is the 2003 - IMHO the twin discs on the 2004 onwards bikes would be too fierce in sand - though I've never ridden one. Note that the rally LC4's only have a single disc.

If I was buying a 2002 or earlier I'd get the mainshaft bearing (behind the clutch) changed - I just had mine changed and apparently the old part was just about collapsed.

You might also find the 'switchable' digital ignition box useful on 2002 or earlier models. There's one fitted as standard on 2003 onwards Adventures. Having said that, I had one fitted and never used it in '80' mode in 5 months in NW Africa. One setting is for '80' grade fuel, the other for '95' - but most of the fuel I found was '90' - and the bike seemed to run better on the '95' setting.

Next mod I'd consider on all models is to use a steel or 'stealth' type rear sprocket - I've also found DID 520VM X-ring chains last a long time. My current gearing is 16 teeth front, 45 rear.

Tyre security bolts/rim locks are something else you might consider if you'll be running low pressures - you can buy these as a KTM part.

I use rally footrests, again available as a KTM part - but I believe the 04 onwards Adventures have wide footrests as standard.

Fork gaters I'd also consider as essential - neoprene ones are available as a KTM part.

Hope this helps.
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  #3  
Old 8 Apr 2005
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Hi again,
... couldn't resist chipping in !

btw, Susan's KTM is a 2002 as you know but it has these mods:

rally footpegs
front and rear tyre rim locks
heavy duty inner tubes
30mm handle bar risers
KTM enduro / competition silencer
Airbox modification (allows more air through) for the above silencer
Touratech front headlight cover
spare clutch cable (wired in position)
Touratech pannier frame / rack for Zega boxes
new MT21 tyres
new 42 rear sprocket
new chain and standard front sprocket

It has a full KTM Sommer rally bashplate with tool boxes but she is going to keep that for another project bike, could be sold with the bike at cost though if you need it. These are great bashplates (6mm ali) and the toolboxes are big enough to hold everything you need other than tyre leavers.

True the bearing has not been changed and it doesn't have fork gaitors. Apart from that is has all the mods you would ever need.

I've ridden the bike quite a bit but I also have a 2003 model myslef. I'd say the performance is almost identical although I prefer the hydraulic clutch on the 2003 to the cable on the 2002. But the 2002 is a very reliable machine.... and a 2003 / 2004 will cost a lot more money too. Oh, the other thing is that the 2003 has a more comfortable seat but you can buy one of those for about 130 euros and it will straight onto the 2002 model (which has a pretty narrow, hardish, enduro style seat).

I think that covers it. If I was going to buy another KTM and I had five or six grand to spend I'd persoanlly get a 2003 2004. But if you have two and a half or three grand to spend the 2002 are a very good buy compared to anything else you could possibly get in that price bracket,

cheers,


Simon
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  #4  
Old 9 Apr 2005
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Hey Simon Thanks !!!
I had a chat with Susan the other evening and will hopefully be up for a look soon.

Keep the opinions/points of view coming though Guys....
All Info Appreciated.
Cheers
Grif
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  #5  
Old 10 Apr 2005
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Sounds like you've got a 2002 in mind. Anyway, here's a summary of major changes to LC4 Adventures from 1997 to 2005 (to the best my knowledge - I accept no reponsibility for errors...):

1997 620EGS-E Adventure, all orange, 609cc, low-slung twin silencers, Dell Orto Carburettor, WP Extreme forks.
1998 Changed to 640LC4 Adventure R, orange and blue, 625cc, high level pipe.
2000 Change to Mikuni carburation (this may have occured in 1998 or 1999 - all I know is that a friend has a UK 'T' registered bike with a DellOrto, my 2000 had a Mikuni), slightly different colour scheme (all blue seat, tank graphics 'reversed').
2001 USD 48mm front forks, new colour scheme (orange back, silver front), adopted rear subframe and panels, fenders from 640LC4-E, new opaque screen.
2002 Slightly different colour scheme (the 'KTM' on the tank became black), new type of tripmaster incorporating coolant temperature and fuel 'low' warning.
2003 New colour scheme silver and black, 'high flow' cylinder head, dual curve CDI, hydraulic clutch, exhaust pipe (still high level), oil level window in primary drive cover, new mainshaft bearing, bigger oil filler screw on frame, possibly new battery and fusebox, more comfortable seat.
2004 New orange colour scheme, low front fender, twin front discs, wider footpegs, black wheel rims, locking fuel cap.
2005 New oil feed line to base of piston, smaller indicators.

There's also been other minor changes - owners or ex-owners might like to comment.

All models come with an engine guard, handguards, small luggage rack and from 98 onwards a mainstand.

I'd give yourself time to get used to the bike, especially if you're changing from a Japanese make. I switched from a Tenere to the Adventure, and initially regretted it - until I took the Austrian machine to Africa.

Apart from the mods/accessories I listed above, you might also consider fitting a sidestand - on the 2000 model there's a tab already on the frame for this purpose, and you can buy the stand itself from KTM. However, when I used this on my 2000 the machine tended to fall over when the suspensions settled when loaded up, even on perfectly level ground. On my 2002 LC4-E I have the SW-Motech stand (bought from Sommer KTM in Germany) - this is of the automatic flip up variety - it can be painful if it catches your leg when flipping up but better than nothing.

Many riders also fit a different silencer - the original, although good quality, is relatively heavy. You have a wide choice, probably the best IMHO is the complete titanium system from Akrapovic, but a cheaper option is either the SXC silencer or the Akrapovic 'slip-on' silencer, all available from KTM.

Another popular accessory is a guard for the headlights - you can buy one from Touratech.

Finally I'd fit either a hadlebar crossbrace and/or the roadbook carrier from KTM, as somewhere to mount your GPS, or your roadbook holder if you have one.

You could easily spend £1000s on other modifications - rally engine guards, steering dampers, different carburettors, side tanks - the list goes on.

You might also consider a 640LC4-E - slightly lower and lighter than the Adventure. Some editions come with an 18 litre tank as standard, otherwise you can add one or a 28 litre tank.

[This message has been edited by Ian (edited 09 April 2005).]
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  #6  
Old 12 Apr 2005
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Ian,
Thanks for all the info - very informative.
Cheers
Grif
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  #7  
Old 22 Apr 2005
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Quote:
Originally posted by Ian:
There's also been other minor changes - owners or ex-owners might like to comment.
Just bought a 2005 model; here are the changes I've identified.

It has 15mm handlebar risers standard.

The fuel tank capacity is quoted as 25.5L rather than the 28L for the earlier models. The 2004 model probably has the 25.5L tank too, since the tank is not listed as being new in 2005 - just the decals.

Also "new" for 2004, according to the sales brochure, are Magura hydraulic clutch, secondary air system (SLS) for "Euro 2" emmissons standard, reinforced outer clutch hub, throttle position sensor. I know some of those things weren't new in 2004!

From the 2005 parts manual, the following are new:

Crankshaft
Rocker arms
Camshaft
CDI unit
Front fender
Rear brake caliper

Hope this helps!



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Cheers,
Colin Campbell
Auckland, New Zealand
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  #8  
Old 22 Apr 2005
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It's interesting to note how many KTM riders have upgraded from the Tenere' (another one here).

A couple of nifty gadgets on the front console of my '04 is the power socket and the dual trip meter (although I think they've all got this)

One minor annoyance is that my rims don't have predrilled holes for rimlocks, so will have to go to the expense of having them drilled in.
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  #9  
Old 22 Apr 2005
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Yep. I'm upgraded from a Tenere too and I think a lot of people are. KTMs are a lot more money... but a lot more bike too ! I think Teneres are getting harder to sell now too, and prices are lower than they were. Which is great if you want one... not so good for those selling !

The 2003 models were the first with electrical sockets fitted as standard, but the 01 and 02s also have dual odometers. The 2002 and 2003 have pre-drilled rims for locks too.... I wonder why they didn't do that for the 2004s ? Odd / studpid !.

Anyway, we could have a bike swap for an hour or so on a greenlane day to see what we each reckon on each bike.... I'm willing to lend out the 2003 in exchange for a go on a 2004 !

I'm keen to ahev a ride on a LC4 enduro too..

Cheers,


Simon
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  #10  
Old 22 Apr 2005
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Got a 2003 model bought in 2004 with a nice discount and already has some 25000km pretty reliable km's on it. i dont feather it, its mainly being used for off-road rides in the weekends and a (one off) trip to the northcape and just keeps on going... Just stick to the Oil and Valve jobbies

Depending on your budget, I would go for '03, '04 or '05... They all got the looks, the 04 and 05 stand out a bit if u go bush camping in West Africa....


BTW, I upgraded from a Dommie, BIG difference!

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[This message has been edited by gozell (edited 22 April 2005).]
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  #11  
Old 22 Apr 2005
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Noticed this trip report?

http://www.advrider.com/forums/showthread.php?t=75752

'03 through western africa
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  #12  
Old 23 Apr 2005
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'Nother tenere/KTM convert.....

Loved the tenere, but felt it was struggling a bit in the suspension setup area.

Have been searching for a 2003 640 for months, just found one!!!! Will be available for rides in about 1 week after I pick it up!!!


Dave
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  #13  
Old 22 May 2005
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Looked almost everywhere on this site and can't find some more info on a 640 2001 model.
Maybe this topic has been discussed before. Any advice welcome, should i buy one or save a bit more. Old Q any problems?
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