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  #1  
Old 11 May 2005
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Vibratttttiiiiiioooonnnn......

Bloody hell these 640's vibrate a bit dont they!!!

I know I can get used to it, but I'm a bit concerned about the trail of bits I'm leaving behind!

So far its a number plate screw, a suspension bolt, an underseat bolt, and yesterday my rear brake light cover (red plastic thing) disappeared!!!!

All that in only 300 miles!!

At this rate I'll be lucky to have any bike left by the time I reach any off road riding!

Have begun a program of nut/bolt removal and threadlocking.

Anyone else lost any vital bits?

DDDDDDave

[This message has been edited by davidlomax (edited 10 May 2005).]
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  #2  
Old 11 May 2005
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Location: Flagstaff,AZ U.S.A.
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Dave-The 640 model will mellow out a bit with mileage.You will notice a big increase in gas mileage,and a clutch,and gearbox that works much easier with a few thousand KM's on the odometer.You might experiment with a few carb adjustments(a bigger main jet,needle height,idle speed,idle circuit).The factory settings are way too lean.I've found that using lower octane fuel(87 in The U.S.)makes the engine easier to start,especially in damp,chilly weather.Also,you need to get rid of the smog cannister,and the clear plastic tubes connected to it.The tube that runs from the gas cap under the gas tank will get pinched and cause the engine to run rough,or not at all.And finally,yes you will need to Loc-Tight everything.Also,the mounting hardware that holds the back edge of the gas tank must be secured with Loc-Tight(don't lose these pieces,they are almost impossible to replace on a trip-I always carry a spare set).
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  #3  
Old 11 May 2005
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I must be lucky, mine's not so bad! (Well nothing's actually fallen off yet)
I would recommend a LED stop/tail light though. Good quality lamps are ok, but cheaop ones from service stations don't last at all well.
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  #4  
Old 11 May 2005
Ian Ian is offline
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Be aware that the US models may be jetted differently to the European models. The US bikes may have a different silencer as standard. The Euro bikes don't have the cannister (to catch fuel fumes?), at least my 00 and 02 LC4's didn't.

I found the stock Euro jetting didn't give any problems - if yours is a 2003 model it may be different due to the High-Flow head.

I've just fitted the KTM airbox cover with appropriate jets supplied by Sommer. This is in combination with the Akrapovic slip-on silencer with db-eater fitted. I'll undo this change if it increases fuel consumption too much. I haven't noticed any change in engine vibration.

Dave - you might like to try fitting handlebar end weights. I have some (from a Duke I think) which I'll trade for 2 pints of at the HU meet if you're going.
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  #5  
Old 11 May 2005
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I almost lost my sidestand!!
Now struggling to get replacement bolts.

Ian, I like the idea of handlebar weights. Mist look into that.
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  #6  
Old 12 May 2005
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Loctite 243!

For more serious vibration prone stuff like the sidestand its 2701 (from memory), needs heating if u want to remove it... 243 will not last on the sidestand for long ....
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  #7  
Old 12 May 2005
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Bloody hell!!!! I've bought a self destruction machine!!!!

Yep, I'll be at the HU meet, and yep, I'd love to trade the bar ends for a few s!

I've also heard it said that removing the bash plate when road riding reduces the vibrations, anyone heard much about that?

Dave

When we're talking Loctite 2701 we're talking serious problems!!


Oh yes, and I love petesonhisway's philosophy, thats my kind of talk.....you don't cut your spoon handle in half and drill holes in it to lighten it too do you!!!

[This message has been edited by davidlomax (edited 11 May 2005).]
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  #8  
Old 13 May 2005
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Yes... don't they vibrate !

But over time they vibrate less than when new. I got my 2003 with just 800 miles on it and it was a bitch. 30 mins and I'd have to stop to get the feeling back into my fingers and arms.

But now (12000 miles later) it is much better. I've also replaced the handgrips with foam ones and replaced the footpegs and rife in soft soled boots. Some people reckon that lead shot in the handle bars helps but I've not tried that.

.... and.... yes, you do get used to it

Oh and I also found that 4500 revs was the wrost spot for vibration so just avoid that... have to go faster or slower !

Simon
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  #9  
Old 13 May 2005
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Ok, so now you've got me worried - is my 640 a dud? Nothing has vibrated loose on it, the only issue has been blown rear light bulbs. I have never loctited anything on it except for the clutch hub nut.

Do you think someone sold me a cunningly disguised Honda? Good disguise, mind, making the mainshaft bearing wear out so quickly.

Dave - you must have a go on mine at the HUBB weekend, see how much difference there is? Or maybe I'm just used to being shaken about - retired classic racer!

Cheers
Neil
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  #10  
Old 13 May 2005
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Pete,
I mounted my GPS on the KTM road book holder, you can see a picture of it on Sommers web page under the items for the Adventurer. It mounts the GPS right up front and makes it easy to view. I don't seem to have problems with vibrations that others have mentioned but the mount is very rigid so it should work well.
If you need I can post a picture for you.
Steve
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  #11  
Old 13 May 2005
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Yes I used Touratech Mounts.
When I first got the KTM I had a Garmin V, now I am using the Garmin 2610.
Steve
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  #12  
Old 15 May 2005
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Ok guys,

'Also,the mounting hardware that holds the back edge of the gas tank must be secured with Loc-Tight(don't lose these pieces,they are almost impossible to replace on a trip-I always carry a spare set). '

What else do I need to carry that's 'Impossible' to replace, but will most likely eject itself at the first sign of corrugations? I learned by experience on my XR and XT, perhaps a little inside information will ease up those 'special visits' to dodgy dealers in the most unlikely locations!

Also whilst doing a little work on the bike the other day I noticed I needed to use a 7mm socket...!!! What other delightful 'non-standard' fasteners am I likely to meet on my travels.

Finally, anyone using those stainless mesh everlasting filters? If so, opinions please...

Cheers,


Dave

Six weeks to go........
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  #13  
Old 15 May 2005
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Pete,

Been cutting and drilling my spoon for years (thats why I mentioned it!)

My bike is a 2003 model so it has a hydraulic clutch, the spockets are about to get changed, together with the tyres. The trip is a real quickie (as all mine tend to be...oooooh Errr!!!). Just three weeks. I hope to do it all on one single service, so no new drain plugs will be required.

You can NEVER teach me to suck eggs! 'cos, I know nothing! Any advice is good advice.

Finally, as for the travel weight issue, I am a true member of the 'Crane Brothers School of Travel', if you're not sure what that is, get a copy of Richard Cranes 'journey to the centre of the earth' or, 'running the himalayas'. I guarantee no matter how light weight you are, you'll realise there are some real SICK puppies out there!!!!

Dave

If you need more than 25 litres of space on any trip.....you're doin' it wrong!!!!

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  #14  
Old 15 May 2005
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After two longish trips on LC4s here's the spares I carry:

Spark plug.
Chain master link.
Front inner tube.
Oiled air filter element.
125ml air filter oil.
Clutch cable (mounted in line with clutch cable on bike).
Throttle cable inner and solderless nipples of the correct size.
Clutch lever and perch.
Wheel bearings.
Brake pads.
Ignition box (actually the original as I have a switchable one).
Radiator hoses.
Fuel hose.
Spokes.
Assorted fasteners, nuts, hose clamps.
5 metres lockwire.
Quicksteel putty.
Gaffer tape.
Oil filter set.
Length of PVC tube (for filling oil reservoir) and funnel.
Rema puncture repair kit.
Tube of superglue.
Tube of instant gasket.

Of course if your trip is shorter then you might need less and if it's longer...

I can't think of any spares that I carry that I wouldn't carry on another bike.

I must be lucky - the only thing I can think of that's vibrated loose is a bolt that held on one of the tank mounting rubbers near the ignition coil (cue everything vibrating off next ride). And I've never had a clutch cable snap. This in about 13000 miles of mixed on/off road going, even some competitions. I don't use thread lock other than where it says to in the manual. But I do torque every fastener (and I really mean all of them) to the correct setting from the manual, except of course for field fixes, but I still correct any settings ASAP.

I'll publish my experience-won tools list if you really want.

I'd be interested to know which fastener has a 7mm head - I've never encountered one and done just about every maintenance task on my bike short of a complete engine strip down.


[This message has been edited by Ian (edited 15 May 2005).]
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  #15  
Old 19 May 2005
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I sold the first one i bought new after only 4 months because i couldn't hold my teeth together.

It didnt smooth out at all after 8,000 miles.

I have found a wide variation in how much they vibrate. I tested four secondhand ones before I found a really smooth one.

Apparently, this is because KTM have only one set of weights for the 625, 60 and 660 motors so the smoothness is a combination of luck on the tolerances.

I bought another new one and Swampy balanced the engine after 1,000 km so it's as smooth as possible.

But things still fall off. It's all part of the fun.

Enjoy your trip!



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Jerome

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