I own a 640 adventure and its a great bike, dont be put off with the vibes, these go away drastically when engine gets up to temp. It will see off most other big singles and is far more off road orientated straight from the crate. Best big single I've ever rode or owned, and I've had quite a few!

Ktm 500 stock weight 111 kg is without: 30l tank, handguards, massive oil filter, working well headlights, mirrors (ktm weight is meassured without street legal kit like mirrors, blinker lights, horn, becouse "it's ready to race"), passenger footpegs and much stronger chromoly subframe, bigger radiators and more coolant, longer-more stable wheel base, dual rotors in front (pre2003 had one rotor), proper airbox, big comfy double seat, carburator which you can adjust and service/repair anywhere, cushin rear wheel hub with dampers (prevents chain wear and some vibrations in low rpm). When you add it all up you end up somewhere around 125kg at best. In my opinion: Long trip (months,years) = ktm 640 2001-2007. Service is pain in the ass but you dont need fancy tools or spare fuel pump or injector if something goes wrong. Big downside of 640 is cluch master cylinder with mineral oil. There are many reports of leaking and getting air in system (1998-2002 had cable clutch). Also 640 had problems with needle bearing of rocker arms wearing quickly which could end up badly. Another thing is auto-decompresor on camshaft also wearing fast. Short trip (one, two weeks) = ktm 500 exc. It's light and gives more fun in dirt. Service is easier but more frequent. You need a lot of stuff to convert it for adventure. Shock need stronger spring for laguage. Same with front forks. Subframe needs to be reinforced or made from different material then aluminum. Rear wheel is 2.15 so lot less adventure tires to choose from. Fuel injection is great but you cant repair it in field. Just my 2 cents ;P

awesome video! 165000km on my old 2005 sixfoddy, she never left me next to the road (or off)

6:00 Correct @it needs to be bleeded But there is nothing like "correct pressure". After you change the oil, you screw back the bolt approx. 1-turn, start the engine, wait until the oil starts to come out pass that bolt, let it drip past for say 20seconds, and then just tighten the bolt.

Nice touch, particularly for an old fart like me. The 640 ADV is a fantastic machine for carrying heavy loads at high speed off road. Yes its a bit of a tractor compared to a twin, but twins don't go where these go. Its also super reliable as long as you sort it yourself to work out any old gremlins.

Yeah I have the 625 equipped with a 620 adventure tank and home made "tower". The big oil capacity as well. Its a great bike for both some serious offroad and road hauling with a bunch of luggage. Engine is strong.

Great video... I'm just waiting to get a plate on my 07 640 adventure. Coming from a T700. Its going to be a good summer

I have had an 03 since about 2006. There is literally nothing like it. One thing not mentioned here is the fact that it has a ton of suspension travel. And no other ADV bike built has anything that compares. Not until you get into modifying more of a dirtbike/ enduro bike. And that tank! The range is close to 400miles. And depending on where you ride this can be HUGE. In the desert west where i live it is easy to put together backcountry trips that are over 300 miles. Try that on a 790 or 701 that is stock. It is really a bummer that KTM did not continue this bike. It was super rare when it was in production and now is truly a modern classic. Everywhere I go people geek out on this bike. I have not ridden mine in over 10 years. And this winter I got it out and have been getting it ready for a summer of riding. I am pretty excited.

Actually the engine capacity was the same (625cc) and 640 was like a model name. There are also 660 lc4 engine with little bit longer stroke and 1mm bigger bore. By the way, i'm lucky to own both those bikes. 1998 Adv R and 2013 500cc

I love the 640 adventure. It was actually the first off road bike I ever rode.

I have 07 KTM 300exc,13 450 six days,14 1190 r.Fun bikes,but i just bought a 05 640 for shed.Had to have one,legend bike.Watching from Australia.

Tanks always looked exactely the same, but changed from 28 to 25litres. Engine was 625cc all the way through. 1998-2003 has single front disk. Rear plastics changed in 2004 aswell as final drive ratio.

Great videos Paul. That bike was the only real single cylinder truly adv ready bike straight out of the box. I had an older one with the single front disk brake. Very tough bike. However I would suggest getting on one and making sure you can live with the vibrations, it’s tractor like. Btw that gear lever for a brake pedal threw me off at first! maybe waiting for a replacement…

Great video of two of my favourite bikes! Thanks!

The 640 Adventure is an unique bike. The only out of the box, long range, off road ready adventure bike. Why didn’t KTM make a 690 Adventure?

I have always wanted a 640 adventure, when I could finally afford one I couldn't find a good one and ended on the 990 adventure, which was Amazing also, but I still have an itch for the 640.

I have a 2001 LC4 640 and I love it. I have ridden two up in the mountains of Colorado and it did amazing. Nick named "Mullie" after pulling me in & out of log roads in Eastern Ky & KAT. I like having a kick for those dead battery stalls in the middle of a farm pond. Or other places, I guess.

Great video. Thanks for the info. Love my 640 Adv. one thing I would say is mine is very easy on fuel. Around 4.5 - 4.8 litres per 100 kilometres

The fact this was the perfect adventure bike is why KTM stopped selling them. It would most likely slow the sales of the flagship adventure bikes. It’s all about $$$$$$.

I always love the 640 adventure, I’m going to sell my 2014 660 Tenere so I can purchase one. I had Ktm 98 400 supercomp lc4 setup for adventure it was great the only downfall no battery just a kick starter with poor lighting love the LC4 engine

Now we get the 790 and 890 adventure... How far we've fallen xD

Thanks for yet another super informative video.

So to sum it up its a really rare bike not many made, but lots made so spares are really easy to get hold of

Also, my sxc625 has the oil in the frame and 2 filters, 2.1 litres of oil.

Amazing motorcycles. The best choice will depend on the rider's preference. I would like to have both.

Wow was just looking at a 640 adv and then this video popped up

Great video thanks

What kind of exc is that.i owned bunch of dirtnikes,hard enduro bikes and also 636 ninja and filers sp1 125 replica,but most of my life were hard enduro and motocross,over 30 bikes in 20 years.But I never ever saw exc that looks like that....for fact with start of new year I’m buying adventure(for 1st time,because it was always cool looking bike,specially the ones from end of 1990 into mid 2000s....damn always wanted to own one.)But now when seeing this exc 500,my God what a machine,I’d love to have one.But I never even saw one for sale or never saw any in races.

They never changed the cc. It was always at 625, they just changed what they call it. Like the 500/520/525 I believe...

Hi Paul, I assume you drive the Motoz 140/80 18 tyre on the rear wheel. Do you use the standard 2.15 rim or the wider 2.5 rim? THX

I'd be interested in knowing what foot pegs are on the 640. Those are not OEM.

Do you know if the 530exc would make a good bike for occasional multi day trips? If so what mods would be needed to help prevent any failures Cheers

I have a line on a 2003 640 adv with 20k miles. Where is the best place for parts? They seem hard to find.

I actually had a 640 (2007) and currently own a 500 (2012). Altho the 640 is a very awesome bike, the 500 is a better bike in most categories.

I really want to buy it 640 for my around the world trip, please reply me if this is possible

Mate what do you mean oil in the fame?

Motorcycle year?

Iam going after one 640 adv this wesd. Hoppe its in good conditions

what is that crazy rear tyre on the exc?

Non venderò mai il mio 640 adv 😎

Man, 7.4 gallon tank - do they get really poor gas mileage or something?

the problem with the 500 is it drinks oil

I had one and put about 30,000klms on it. NEVER again. Great bike overall but holy crap it'll vibrate the fillings outa your teeth.