KTM 640 DUKE II 2003 Page 45 Owner'S Manual Download

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ENGLISH

Page

Activating the ignition curve for low-octane fuel . . . . . . . .15

Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Bleeder screw front fork . . . . . . . . . . . . . . . . . . . . . . . . . .19

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Changing the basic position of the foot brake pedal . . . . .25

Changing the basic position of the handbrake lever . . . . .24

Changing the original position of the clutch lever . . . . . . .33

Changing the spring preload of the shock absorber . . . . .20

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Check the following before each start . . . . . . . . . . . . . . . .11

Checking and adjusting the choke cable play . . . . . . . . . .33

Checking and adjusting the steering head bearing . . . . . . .19

Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Checking of brake fluid level - front brake . . . . . . . . . . . .24

Checking the adjustment of the hand decompression cable .33

Checking the cooling liquid level . . . . . . . . . . . . . . . . . . . .32

Checking the damping rubbers in the rear wheel . . . . . . .27

Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .34

Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .24

Checking the oil level of the hydraulic clutch . . . . . . . . . .33

Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .25

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .25

Checking the rubber ring of the rear shock absorber . . . . .20

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Cleaning the dust sleeves of the telescopic fork . . . . . . . .19

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Compression damping of fork . . . . . . . . . . . . . . . . . . . . . . .9

Compression damping of shock absorber . . . . . . . . . . . . . .9

Conservation for winter operation . . . . . . . . . . . . . . . . . . .40

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Correcting chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .21

Dismounting and mounting the front wheel . . . . . . . . . . .26

Dismounting and mounting the rear wheel . . . . . . . . . . . .26

Draining of float chamber of the carburetor . . . . . . . . . . .34

Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .5

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Flasher - replacing the bulbs . . . . . . . . . . . . . . . . . . . . . . .30

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Page

General information about KTM disc brakes . . . . . . . . . . .23

General tips and warnings for starting the motorcycle . . . .10

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . . . .5

Headlight - replacing the bulbs . . . . . . . . . . . . . . . . . . . . .30

Headlight range adjustment . . . . . . . . . . . . . . . . . . . . . . .30

Ignition lock with 3 switch positions . . . . . . . . . . . . . . . . . .6

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Instructions for initial operation . . . . . . . . . . . . . . . . . . . . .10

Kickstart instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Lubricating the shock absorber linkage . . . . . . . . . . . . . . .20

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Maintaining chain tension eccentrics . . . . . . . . . . . . . . . . .22

Maintenance work on chassis and engine . . . . . . . . . . . . .18

Oil and screen filter change, bleeding of the oil system . . .35

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Opening the headlight mask . . . . . . . . . . . . . . . . . . . . . . .29

Operation instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Parking light - replacing the bulb . . . . . . . . . . . . . . . . . . .30

Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . .16

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . . .9

Rebound damping of shock absorber . . . . . . . . . . . . . . . . .9

Refilling the front brake fluid reservoir . . . . . . . . . . . . . . .24

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . . .25

Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Serial number locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Starter tip switch, emergency OFF tip switch, light switch . .7

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Starting when the engine is cold . . . . . . . . . . . . . . . . . . . .12

Starting when the engine is warm . . . . . . . . . . . . . . . . . . .12

Stop light and tail light - replacing the bulb . . . . . . . . . . . .31

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Supporting strap for the passenger . . . . . . . . . . . . . . . . . .18

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Technical data – engine 640 Duke 2003 . . . . . . . . . . . . .41

Technical specifications - chassis 640 Duke 2003 . . . . . . .42

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

What to do when the engine is „flooded” . . . . . . . . . . . .12

Wiring diagramm . . . . . . . . . . . . . . . . . . . . . . . . . . .appendix

HEAD WORD INDEX

Summary of Contents for 640 DUKE II 2003

Page 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art Nr 3 210 58 2 2003 640 DUKE II...

Page 2: ...moval or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise...

Page 3: ...and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM sh...

Page 4: ...edule must be performed and service records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specifi...

Page 5: ...ing chain tension 21 Chain maintenance 21 Chain wear 22 Maintaining chain tension eccentrics 22 General information about KTM disc brakes 23 Changing the basic position of the handbrake lever 24 Check...

Page 6: ...only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the next attempt This is due to the fact that the automatic decompres...

Page 7: ...when the flasher light is working in the same rhythm as the flasher light Faster flashing of the flasher control lamp indicates a defect bulb The blue indicator lamp lights up when the high beam is o...

Page 8: ...switch has 3 positions Light off Parking light on Headlight on The emergency off switch 6 is provided for emergency situations and should not be used to switch off the engine The engine is ready for o...

Page 9: ...uel next time too CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE Shift lever The shift le...

Page 10: ...amping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far...

Page 11: ...ith protective clothing and helmet Pay attention to running in instructions Running in Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a lon...

Page 12: ...reservoir If the level of brake fluid falls below the mini mum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KT...

Page 13: ...ler WARNING WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH IF THE ENGINE...

Page 14: ...M RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FU...

Page 15: ...is solid and that your motorcycle is standing securely Just in case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE THE SIDE STAND AND OR THE...

Page 16: ...to the CDI box If the two connectors are connected to each other the ignition curve for fuel having at least 95 octane ROZ is activated If you disconnect the plug and socket connection the ignition cu...

Page 17: ...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 adj...

Page 18: ...gular intervals 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 chamb...

Page 19: ...E YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PEN...

Page 20: ...then be released a few turns to let overpressure if any escape from the interior of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motor...

Page 21: ...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 22: ...INDLE BECOMES LOOSENED DURING THE PROCESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hexagon nuts on swing arm fists to 40 Nm...

Page 23: ...ce them To do this Remove rear wheel Loosen hexagon nuts 1 on the left and right swing arm fists Remove eccentrics Clean eccentrics and swing arm fists thoroughly and grease the slide faces with a Mol...

Page 24: ...l thickness Measure the nominal thickness in a location B outside the contact face Check wear in several locations WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SA...

Page 25: ...DOT 5 1 Motorex Brake Fluid 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF...

Page 26: ...r it is recommended to remove the hexagon screw 3 Then move the container outwards as indicated in the illustration Remove plug 4 with rubber boot 5 and add brake fluid DOT 5 1 Motorex Brake Fluid DOT...

Page 27: ...TO PREVENT LOOSENING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE IT IS VERY IMPORTANT TO KEEP THE BRAKE D...

Page 28: ...to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in your country for minimum t...

Page 29: ...LL DESTROY THE RECTIFIER REGULATOR STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C Do not expose to direct sun rad...

Page 30: ...use box The fuses marked RES are spare fuses Fuse 1 10 Ampere protects the following power consuming units ignition starter system Fuse 2 10 Ampere protects the following power consuming units flasher...

Page 31: ...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 32: ...AUTION The red cooling liquid temperature warning light 5 will begin to light up if the cooling liquid temperature reaches approx 110 C and henceforth has exceeded its normal operating temperature Pos...

Page 33: ...ir filter cover from the air filter box Unclap the filter holder 1 swing back and remove air filter plus filter carrier from the filter box Thoroughly wash the air filter in special cleaning fluid and...

Page 34: ...WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Checking and adjusting the choke cable play The choke lever must always have a play of approx 4 mm 0 16 in CAUTION IF THERE IS NO PLAY IN THE CHOKE CABLE THE...

Page 35: ...RM ANY WORK ON THE FUEL SYSTEM IN THE PRO XIMITY OF OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATU...

Page 36: ...n turn may result in engine failure Therefore we recommend that you have the engine oil changed by your authorized KTM mechanic During the guaranty period the oil change must be performed by an author...

Page 37: ...escape turn off the engine and mount the plug together with the gasket Allow the engine to warm up check the engine oil level and correct if neces sary Afterwards check the entire oil system for leaka...

Page 38: ...and emergency OFF switch contact a KTM dealer Replace fuse 1 Remove seat and replace the main fuse If fuse blows again contact a KTM dealer Contact a KTM dealer Contact a KTM dealer Open fuel tap tank...

Page 39: ...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 40: ...gnition power consumer hasn t been 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...

Page 41: ...cylinder 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...

Page 42: ...84 V03 1 Valve diameter Intake 36 mm Exhaust 32 mm Valve clearence cold Intake 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end beari...

Page 43: ...el floated 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 rea...

Page 44: ...1 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 bolts with nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swing arm bolt M14x1 5...

Page 45: ...chamber of the carburetor 34 Driving instructions 11 Engine number engine type 5 Engine oil 34 Filler cap 7 Flasher replacing the bulbs 30 Foot brake pedal 8 Fuel tap 8 Fuses 29 Page General informati...

Page 46: ...ANHANG APPENDICE APPENDIX AP NDICE 1...

Page 47: ...itch horn switch flasher switch 0 1 2 light switch diode rear brake switch ignition coil diode 2nd 3th N sidestand switch 3th gear 2nd gear neutral switch right front flasher front brake switch headli...

Page 48: ...nterruttore folle Octane selector Oktananpassung Adattamento anticipo agli ottano Pick up Impulsgeber Pick up Rear brake switch Hinterer Bremslichtschalter Interruttore luce post di stop Rear light br...

Page 49: ...ral switch Contacteur de point mort Interruptor de ralent Octane selector S lection pour l indice d octane Ajuste de octano Pick up Capteur d allumage Generador de impulsos Rear brake switch Contacteu...

Page 50: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321058...

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