KTM 640 DUKE II 2001 Owner'S Handbook Manual Download Page 40

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ENGLISH

Collar nut front axle

M17

40 Nm

(30ft.lb)

Collar nut rear axle

M20x1,5

80 Nm

(59ft.lb)

Shock absorber top

M10

45 Nm

(33ft.lb)

Shock absorber bottom

M10

45 Nm

(33ft.lb)

Collar screws brake disk front

Loctite 243 + 10Nm

(7ft.lb)

Collar screws brake disk rear

Loctite 243 + 10Nm

(7ft.lb)

Screw brake caliper front

Loctite 243 + 25 Nm

(19ft.lb)

Allan head screw brake caliper front

M10x1,25

Loctite 243 + 45 Nm

(33ft.lb)

Allan head screw brake caliper support rear

M10

50 Nm

(37ft.lb)

Bearing bolt linkage arm/frame

M12

60 Nm

(44ft.lb)

Collar nuts rocker arm bolts

M14x1,5

100 Nm

(74ft.lb)

Engine mounting screw

M10

45 Nm

(33ft.lb)

Ball joint for push rod

Loctite 243 + 25 Nm

(19ft.lb)

Sprocket screws on nuts

Loctite 243 + 35 Nm

(25ft.lb)

Collar nut swingarm bolt

M14x1,5

100 Nm

(74ft.lb)

Clamping screws top triple clamp

20 Nm

(15ft.lb)

Clamping screws bottom triple clamp

15 Nm

(11ft.lb)

Clamping screws fork stubs

10 Nm

(7ft.lb)

Collar nut for eccentric chain adjuster

M10

40 Nm

(30ft.lb)

Screws handlebar clamp

Loctite 243 + 20 Nm

(15ft.lb)

Allan head screw handle bar support

M10

Loctite 243 + 40 Nm

(30ft.lb)

Other screws on chassis

10 Nm

(7ft.lb)

25 Nm

(19ft.lb)

M10

45 Nm

(33ft.lb)

Other collar nuts on chassis

15 Nm

(11ft.lb)

30 Nm

(22ft.lb)

M10

50 Nm

(37ft.lb)

TIGHTENING TORQUES - CHASSIS DUKE II

Summary of Contents for 640 DUKE II 2001

Page 1: ...OWNERS HANDBOOK 2001 BEDIENUNGSANLEITUNG 640 DUKE II Art Nr 3 205 99 11 2000...

Page 2: ......

Page 3: ...a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose...

Page 4: ...over to the new owner Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this Owner s Handbook to carry out most of the maint...

Page 5: ...level front brake 20 Refilling the front brake fluid reservoir 20 Checking the front brake pads 21 Changing the basic position of the brake pedal 21 Checking the rear brake fluid level 21 Refilling th...

Page 6: ...This is due to the fact that the automatic decompressor doesn t work properly If this happens pull the manual decompression lever and start again Afterwards normal starting will be possible b When yo...

Page 7: ...AXIMUM RECOMMENDED ROTATION RATE IS 8500 RPM ROTATION RATES EXCEEDING 8500 RPM WILL SHORTEN YOUR ENGINE S LIFE REFER ALSO TO THE SECTION ON RUN NING IN YOUR MOTORCYCLE TO BE FOUND IN THE DRIVING INSTR...

Page 8: ...to position and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Combination switch Th...

Page 9: ...AUSE IT MAY DAMAGE THE ENGINE WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETT...

Page 10: ...METHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Compression damping of fork Hydraulic compression damping de...

Page 11: ...D BE THE RESULT Seat lock The seat is secured by the lock on the side of the seat 3 REMOVING THE SEAT Put the ignition key into the lock Turn it counter clockwise all the way to the stop to unlock the...

Page 12: ...in the tachometer Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine Check the following before each start...

Page 13: ...t is on ignition lock in position If this is not the case the battery is discharged If the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer WARNING WHEN START...

Page 14: ...ES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A BENT HANDLEBAR MUST ALWAYS BE REPLACED NEVER TRY TO STRAIGHTEN T...

Page 15: ...Y GRASS OR OTHER EASILY FLAMMABLE MATERIALS CAUTION PARK YOUR MOTORCYCLE SO THAT IT RESTS STABLY ON THE SIDE STAND HARD GROUND LEVEL SURFACE AND CAN T TIP OVER CLOSE THE FUEL TAP WHEN LEAVING YOUR VEH...

Page 16: ...l tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Check ad...

Page 17: ...als Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify sm...

Page 18: ...hould be greased WARNING MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM D...

Page 19: ...mm A spring preload Checking the rubber ring of the rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibration damper This ring gets pressed together with time and lose...

Page 20: ...move upwards CAUTION IF THE WHEEL SPINDLE BECOMES LOOSENED DURING THE PROCESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hex...

Page 21: ...AS POSSIBLE CAUTION IF THE ECCENTRICS ARE NOT ALIGNED THE REAR WHEEL WILL REST AT AN ANGLE IN THE SWING ARM THIS WILL STRESS THE REAR WHEEL AND SWING ARM BEARINGS AND DAMAGE THEM IF NOT CORRECTED Gene...

Page 22: ...S BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY CHANGE BRAKE FLUID AT LEAST ONCE A YEAR IF THE MO...

Page 23: ...uretor connection boot The brake fluid level may not drop below the MlN marking when the vehicle is in an upright position WARNING IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYS...

Page 24: ...e speedometer drive To mount the front wheel insert speedometer drive into the front wheel Lift the front wheel into the fork and position the speedometer drive as shown in the illustration the connec...

Page 25: ...re the tires have in them affect the way your motorcycle rides and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle Tire type and size can be found in the...

Page 26: ...O NOT REMOVE THE LOCKING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR STORAGE When preparing the motorcycle for a longer period of standstil...

Page 27: ...to Exchanging the headlight lamp Fuse 4 10 Ampere protects the following power consuming units headlight parking light Fuse 5 10 Ampere protects the following power consuming units flasher lights brak...

Page 28: ...S OF THE BULB WITH YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE HEAT WILL OTHERWISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR Reconnect the cable plu...

Page 29: ...CAUTION IF THE RED COOLING LIQUID TEMPERATURE WARNING LAMP 5 LIGHTS UP THIS WILL MOST LIKELY BE DUE TO A DEFECT IN THE COOLING SYSTEM IN THIS CASE STOP IMME DIATELY AND TURN OFF THE ENGINE LET THE ENG...

Page 30: ...ut 1 accordingly Checking the adjustment of the hand decompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kick starter until the cli...

Page 31: ...BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL...

Page 32: ...gs of the engine will not get enough lubrication which in turn may result in engine failure Therefore we recommend that you have the engine oil changed by your authorized KTM mechanic During the guara...

Page 33: ...e oil would get into the air filter box by way of the engine venting system Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING TH...

Page 34: ...cy OFF switch contact a KTM dealer Replace fuse below the headlight mask Remove seat and replace the main fuse If fuse blows again contact a KTM dealer Contact a KTM dealer Contact a KTM dealer Open f...

Page 35: ...ble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Dismount carburetor and check if worn out Replace float needle Replace float Adjust choke cable R...

Page 36: ...een switched off The battery isn t charged by the generator because REMEDY Readjust or replace ventilation hose Check engine oil level when the engine is warm correct if necessary Use thicker engine o...

Page 37: ...inder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slow...

Page 38: ...camshaft camshaft drive through single chain Camshaft 249 1 Valve diameter Intake 36 mm Exhaust 30 mm Valve clearence cold Intake 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing...

Page 39: ...el brake disc 320 mm 12 6 in and 4 piston brake caliper Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in and single piston brake caliper floated Tyres front 120 70 R 17 58H rear 160 60...

Page 40: ...r arm bolts M14x1 5 100 Nm 74ft lb Engine mounting screw M10 45 Nm 33ft lb Ball joint for push rod M8 Loctite 243 25 Nm 19ft lb Sprocket screws on nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swingarm...

Page 41: ...TRUCTIONS 10 Emergency OFF button 6 Emergency OFF switch Australia 7 Engine number engine type 4 Engine oil 30 Filler cap 7 Flasher replacing the bulbs 26 Foot brake pedal 8 Page Fuel 7 Fuel tap 7 Fus...

Page 42: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 320599...

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