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  #1  
Old 14 Jun 2008
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High millage KTM's?

I have been reading up on the 640 Adv alot this page is a great resource, espically the great problems list page, These seems to focus on the problem bikes. Not so much on the bikes that have run happy for along time. So how far can you take them before a rebuild is nessary. My Yamaha 3AJ engine I love because im sure it will clock up 100'000kms before a rebuild, 60'000 now and runns sweet. But I really miss the power. How many of these KTM 640's have happy clocked up 100'000kms? My next trip will be around the world so 100'000km's is proably going to be around about my total distance.
Thanks George.
P.S. This also goes for the 950/990 too. As a twin in theroy they should last londer...?
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  #2  
Old 14 Jun 2008
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Sark, eh? Can't see you clocking up many miles there - unless, you're in possession of a very large treadmill!!) Sorry couldn't resist
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  #3  
Old 20 Jun 2008
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Hope I wont offend anyone with this, because Im just speaking my mind...

I´ve had a friends´ 640LC4 on loan now for 1,5 months, as he´s working abroad, and my own bike´s (still) returning from an overland-trip to Australia.

It seems like a damn complicated machine to use & maintain, considering its only a carburated 1-cylinder bike. I was about to change oil, until I discovered how many steps there are in the procedure, and how many things you can do wrong, unless you know exactly, what youre doing. So I thought its better leave it be.

The thing vibrates like its engine is about to blow up. I know 1-cylinder bikes do vibrate a bit, but this is almost intolerable. A DR650 does not vibrate half as much.

And the strangest thing: if I take my girlfriend to ride as a pillion, the engine starts knocking. Thats right, she´s only like 50 kilos plus her gear, but Im actually reluctant to take her aboard, because Im afraid the engine might not like it in the long round, it starts to sound like you´re doing something you shouldnt do (and I´ve tried different gears/revs, they help a bit, but do not solve this). I do not understand, how you´re supposed to load this thing up, if going on a trip, and the engine starts knocking. Really a puzzling find, but it is clearly there. I even tried higher-octane fuel, doesnt help. I would like to return my friend a bike that still works, so this noise is a bit scary.

In general, this bikes gives me a feeling (about which I could be wrong) that it is not made to last. After having many bikes, which havent failed even once, after tens of thousands of km´s ridden into each, I am more than a little surprised about the way this bike seems to be built.

A guy from Finland rode thru Russia to Vladivostok and back on an 640LC4 Adventure, so I guess its not really that bad after all - and it is a good choice for bad roads no doubt, actually its great! But he told me, that after the trip, he´s now looking at a major engine overhaul, on a bike thats done less than 50.000kms. Some problem with oil circulation or something.

Not very convincing, I must say. Especially if you´re planning to go somewhere, where theres no service available.
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  #4  
Old 22 Jun 2008
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Choose the bike for the trip!

I now own a 2002 640 Adv and did a 2 week tour of ireland.
I would seriously suggest that when you choose a bike for a trip you are honest with yourself as to what kind of riding you are going to do.
The KTM loves dirt and I wouldnt choose any other bike for it.
BUT it hates long stretches of tar!! And so will your arse!
A quick list of problems i had 12 days 2000 miles)
  1. The battery terminal vibrated off
  2. My side stand started to bend
  3. the lower barrel gasket blew and pissed oil
  4. the bike over heated and pissed coolant all over the place
  5. The fan failed to kick in
  6. A fuse vibrated loose and I lost ignition and battery charging?? Try find that problem..
  7. Couldnt sit down for at least 3 hrs after a 250km stretch which pushed my Guiness bill sky high! Plus the reduced range!!!!!
I love my bike. I love looking at it....but I havent been back on it since the trip. Funny that.
For RTW find a bike thats like riding a sofa!
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  #5  
Old 23 Jun 2008
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My experience

My piastres worth based on my experience ( not doubting the doubters ),

Couple of KTM Adventures, no dramas.
Most recent bought from an overlander, who bought from an overlander, been round africa twice, generally overloaded and thrashed, hence needed engine work.

Since that engine work I've ridden over 30, 000 km, 5000 on road to get here, and the rest mostly off road, high stress, including lots of sand. I have changed oil and filters, really that is all. I guess I should check valve clearances soon. Absolutely no dramas.

Sure some of the other guys here have more dramas, so I guess I'm saying you can still get lucky. It is pretty much accepted as being without doubt the best bike for serious desert trips here.

I'll keep crossing my fingers and touching wood, hope I'm not jinxed now.

JT
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  #6  
Old 22 Aug 2008
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Rtw Ktm

Guys,
Just completed a RTW ride on my '02 KTM 640 Adventure following the 45th parallel north. Parts used, one head gasket. The machine has 34k miles at present.

The KTM is a mechanics motorcycle and needs to be prepared properly and worked on knowledgeably. If you don't take the time or have the knowledge to set the machine up properly, yes you will have problems and every 25K miles the machine needs to be freshened up. Do that and you will ride the best handling adventure touring motorcycle in the world.

In Mongolia I saw plenty of broken BMW's and KLR's but no broken KTM's. The 640 is a solid platform. Suspension and drive systems are problem free. The engine if set up correctly has no problems.The cylinder is chrome, valves strong, transmission and clutch with the bearing upgrade is flawless. Dual filters keep the oil clean and the machine will run on any octane gas at any altitude. All components are top quality. Gas mileage is around 50mpg, the tank is 7+ gallons and the airflow around the machine is aerodynamic due to the design of the bodywork.

It is the PhD of motorcycles. The ignorant ride lesser machines.
Power and handling equal saftey.
That is a KTM.
bill.

Anyone with questions can contact me at bmwstbill@yahoo.com or call my cell.
715 966 2001. I live in Tomahawk, Wisconsin USA
Central standard time.
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  #7  
Old 22 Aug 2008
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Quote:
Originally Posted by Bill Shockley View Post
Guys,
<SNIP
In Mongolia I saw plenty of broken BMW's and KLR's but no broken KTM's. The 640 is a solid platform. Suspension and drive systems are problem free. The engine if set up correctly has no problems.The cylinder is chrome, valves strong, transmission and clutch with the bearing upgrade is flawless. Dual filters keep the oil clean and the machine will run on any octane gas at any altitude. All components are top quality. Gas mileage is around 50mpg, the tank is 7+ gallons and the airflow around the machine is aerodynamic due to the design of the bodywork.

<SNIP>
What are these broken BMW's you're referring about? And no broken KTM's? No way...not that I'm a defender of the Roundel...

I know it was a tough winter in Wisconsin Bill...but you gotta put down that KTM Kool-Aid


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  #8  
Old 22 Aug 2008
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Quote:
Originally Posted by mollydog View Post
Edde,
The more relevant question would be: "How many KTM's are out there doing cross Mongolia/Russia trips, or RTW?" My guess is very few compared to BMW's. But if you doubt BMW failures Edde, just check out some of the links on current Dakar vs. F650 thread I've just posted. Funny, the K75 was never singled out for any probs! (I think you picked a good bike!)

<SNIP>

I think I covered the KTM thing pretty well then. Bill's report just re-affirms what I said.

I agree MD and Bill is being a big sourpuss because he wished he had used a K75 on his trip instead of his KTM

All kidding aside...there is no perfect bike.

They all have their issues. When I choose to take on a long trip, I picked a bike who's issues I'm familiar with and was prepared to deal with.

You know the DR and that's a rock solid choice but it has some drawbacks for certain instances. BUT I'm looking for a 250 version to toss around with...so keep your ears open!
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  #9  
Old 23 Aug 2008
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Quote:
Originally Posted by mollydog View Post
The more relevant question would be: "How many KTM's are out there doing cross Mongolia/Russia trips, or RTW?" My guess is very few compared to BMW's.
Patrick
I don't recall that well, but when Sir Edde and Wild Bill were in Mongolia in the summer of '07, there probably was too much of a mishmash of bikes to really pick out more than a handful of KTMs, or of any other brand for that matter.

There does seem to be a dearth of KTM users here on the forum, but as I jokingly mentioned before, the orange plague has spread into Africa and I would guess that it is the most common bike used for trans Africa trips. I realize that it is a snapshot in time and likely a fairly recent phenomenom, but a fairly significant number have been put through their paces on that continent and come through quite well. Their riders swear by them and for off road riders and rugged rides, they are very well suited.

Side note, but another thing that I was unaware of previously was that they have the best dealer coverage by far for all of the north east coast Africa. You can at least pop into a dealer/"quasi-dealer" with some KTM experience and a varying level of parts in Cairo, Addis, and Nairobi. In some of those places, such as Addis, they are the only place with any experience in big foreign bikes, even if it is only run out of a guys garage. The other manufacturers are pretty much not there or only deal in small bikes for the local market. Something to at least consider for all the riders considering Africa.
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  #10  
Old 23 Aug 2008
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Thanks Patrick for the reference to Jean Luc's story. When you mentioned something about losing a bike, it rang a bell and I remember hearing a bit about it from his riding partner, Turkish, whom we met in Buenos Aires in June.

From what I remember, Andy had swung by later to check on the bike but wasn't even allowed near it. I offered to drop in on my way down south to see if it was even still there, but there was really no use as the authorities had it in their hot little hands.

I'll definitely go there and check out the thread. Cheers.
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  #11  
Old 27 Aug 2008
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I've had a pretty good run out of my 03 640 Enduro. It's done 56 000 km now & has never let me down. It's been ridden pretty hard at times, on & off road. I think the 03-on 640's are as reliable as any single, especially given the level of performance.

Mine has been serviced fairly religiously, & that oil change & valve check is a touch fiddly compared with some similar bikes, but an extra 20 minutes in the shed every 5000km doesn't bug me much. In general it's actually quite nice to work on.

In addition to that, chains, sprockets, tyres & the odd brake pad it has had:

1 countershaft seal replaced
Re-sealed on the cam-cover to stop an oil seep
Forks serviced every 20 000km or so
Shock serviced at 40 000km
Lower shock bearing replaced twice & the other swingarm bearings lubed
1 new set of wheel bearings at 50 000km + 2 rear sprocket carrier bearings
New steering head bearings - not essential, decided to do em while I was getting the forks serviced.
1 Battery

At 50 000 km we pulled the head apart to replace the cam follower roller bearings, these are known to wear out at around the 50 000km mark - about the only serious issue common to this motor, & usually easily caught as the valve clearances will start opening up. The intake one was indeed showing the beginnings of some wear. We also chucked in a new timing chain & replaced all the other bearings in the head & the waterpump seal & shaft, although all that stuff was still in good nick the new parts were not too expensive so it all got done. Measured up the clutch & the plates were still at new spec.

It currently needs a new electric starter sprag clutch put in, the kicker works fine until I get around to that.

Parts prices & availability in NZ are comparable to, & often better than, the major jap brands.

With the (cheap!) factory comfort seat on mine I've done plenty of 700km days no worries. Might do the local 1000 mile run on it this year.

It works for me.

Cheers
Clint
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  #12  
Old 28 Aug 2008
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Quote:
Originally Posted by mollydog View Post

Plenty of younger guys will not have a problem with KTM and will accept higher maintenance as part of the adventure.
I'm still not getting this "High Maintenance' thing though, my mate with a DR650, which is renowned for being simple & low maintenance, does the same scheduled valve check & oil change every 5000km that I do on the 640. Suspension service intervals are the same too IIRC. The full extent of the KTM's 'high maintenance' is that the 5000km service takes about 20min longer cos the valves are a little fiddly to get at & there are 2 filters & oil fills.

Less tolerant of poor maintenance? Maybe, I dunno. High maintenance? Not really in my experience.

Cheers
Clint
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  #13  
Old 28 Aug 2008
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I owned and used a ktm 950 adventure 03 model for overlanding trips europe,Russia and Scandinavia. I covered about 45000 miles in total and other than a lot of maintenance (probably over maintained) By that i mean changing things before they go - fuel pump,wheel bearings etc etc the bike was totally reliable, yes parts can be pricey and maintenance is a real chore but for trips where you can do your mileage needed within the service intervals or get away with oil change on route the big KTM is nothing short of superb (Two up with luggage) Travelling solo I would pick a much smaller beast. I would say that the quality of components,(frame suspension etc, engineering and finish are as good as it gets and totally wipe the floor with the likes of BMW and most jap stuff. I have to say through every type of weather climate and landscape the ktm never let me down. They however demand higher and more complex levels of service and maintanence and so unless your well in tune with the bike are maybe not as suitable for round the world stuff (speaking of the 950 here) I think the 640 is fine for such trips.
Am I anti BMW no I own and use a r80gs and love it. Infact I have now sold the KTM simply for the reasons of cost and the more comlex maintanace that would have been needed on the next big trip, the BMW is more suited eg, simple, .cheap parts, easier to ride with my somewhat limited skill on the slippy stuff, basic service in a couple of hours and everything so accesible. A complete exchange gearbox costs little more than a clutch cage would for the KTM, If the shaft drive is suspect stick a new one in its only the price of 3 chain and sprocket sets - the ktm went through that no problem. The BMW is bike of choice for my particular purposes now, The KTM however still remains a superb machine throughout.
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  #14  
Old 3 Sep 2008
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Well done Bill but don't be harsh...

Bill

Congratulations on the epic ride...

But wasn't it you who had a real twitch about which side of the road they rode in some of the far flung places overseas before you started ?? I seem to recall several posts on the subject...

EG" Bill Shockley, Veteran HUBBer, Join Date: Sep 2002, Location: Tomahawk, Wisconsin

Klaus, Grant and everyone,
Thanks for your help. I am open to any possible solution. Japan would be wonderful.
One problem is my big fear of driving on the left hand side of the road.
My friend went to England and rented a car. He was still in sight of the airport when he got in a horrible wreck so I am wondering what will happen to me if I try to drive in Japan.
I do not know which side of the road Koreans drive on. And I just assumed Russia is back to right hand driving.
Well, it's always the minor stuff that messes a guy up like not speaking Russian or Chinese."


And i seem to remember many people giving you reassurance - not criticism...

So why criticise others who choose to ride other machinery as ignorant ?

That's not really in the spirit of our great brother and sisterhood of world travellers
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  #15  
Old 4 Sep 2008
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Quote:
Originally Posted by orrin View Post
For RTW find a bike thats like riding a sofa!
Exactly. That's why I bought not just 1 but 2 F650 Dakar's. Come on Molly, have a crack

Having done a trip on 2 so called bullit proof 3AJ's makes me think I know where you're coming from. We've had our little problems and ours were rebuilt by Dave Lambeth as well. The biggest was the one-way starter gear, weak suspension and thus breaking 3 or 4 caliper brackets. I think the conclusion from that trip was that old fashioned proven technology and design doesn't substitute knowledge of your own machine and being prepared for known faults. They all have them. That and comfort is everything. So we went with the latest and greatest of the current time insteaed. Only really looking at the 640 and the 650 we ended up with the 650. I wanted the 640 because I could take it trail riding on more technical stuff but the Mrs couldn't touch the ground.
The 650 would have been better suited anyway I reckon. Plenty of power in the alternator for all the gear you'd want turning it in a super comfortable smooth travel machine. Motor lasts forever if you look after it without any special needs.

It's all relative. Our lessons were to upgrade the suspension (shock and emulators work well) which you should do anyway with all the added weight and do you homework on all the proved weakpoint. Know your machine inside and out and get the tools needed. Which for the FI bikes should include a diagnostics tool. It's like a photocopier telling you where the paper jam is. I'm happily cured from carbs with their smelly floats and fuel taps pissing out fuel everytime you come off. Last trip we smelled of fuel each day every day.
I reckon I've got everything covered on ours which is good because we're leaving in 9 weeks time.

Yeah it costs more money, but who cares. When you're on your trip it won't matter. Smokers spend a fortune smoking, pissheads spend a fortune on piss, why not can we spend a fortune on a comfortable well laid out bike. Loving the tank under the seat thing BTW. Damn lifting that tank of the 3AJ gave me the shits.

Back OT though. I've seen photo's of a bloke on a Norton Pantera who was a few month ahead of us on our route. If he can keep that thing going, anything should.
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