KTM 640 DUKE II 2005 Page 48 Owner'S Manual Download

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ANHANG – APPENDICE APPENDIX – APÉNDICE

SCHALTPLAN

WIRING DIAGRAM

ENGLISH

DEUTSCH

ITALIANO

Battery

Batterie

Batteria

Capacitor

Kondensator Condensatore

CDI

Clutch switch

Kupplungsschalter

Interruttore frizione

Cooling fan

Lüftermotor

Motorino ventola

Diode

Diodo

Driving light control lamp

Fernlichtkontrolle

Driving light control lamp

EPC

flasher control lamp

Blinkerkontrolllampe

Spia lampeggiatori

Flasher relay

Blinkerrelais

Relè indicatori

Flasher switch

Blinkerschalter

Deviatore indicatori di direzione

Front brake switch

vorderer Bremslichtschalter

Interruttore luce ant. di stop

Fuse box

Sicherungskasten

Scatola fusibili

Generator

Generatore

headlight

Scheinwerfer

faro

High / low beam switch

Auf-Abblendschalter

Commutatore abbagliante/anabbagliante

Horn

Hupe

Avvisatore acustico

Horn switch

Hornschalter

Interruttore avvisatore acustico

Idle control lamp

Leerlaufkontrolllampe

Indicat marcia folle

Ignition coil

Zündspule

Bobina d'accensione

Ignition switch

Zündschloss

Interruttore d'accensione

Left front flasher

linker vorderer Blinker

Indicatore ant. sx

Left rear flasher

linker hinterer Blinker

Indicatore post. sx

Licence plate lamp

Kennzeichenbeleuchtung

Luce targa

Light switch

Lichtschalter

Deviatore luci

Neutral switch

Leerlaufschalter

Interruttore 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 / brakelight

Hinteres Begrenzungslicht / Bremslicht

Luce post. di posizione/stop

Regulator-rectifier

Regelgleichrichter

Regolatore-raddrizzatore

Right front flasher

Rechter vorderer Blinker

Indicatore ant. dx

Right rear flasher

Rechter hinterer Blinker

Indicatore post. dx

Sidestand switch

Seitenständerschalter

Interruttore cavalletto lat.

Speedometer

Tachometer

tachimetro

Start auxillary relay

Starterhilfsrelais

Relè ausiliario d'avviamento

Start relay

Startrelais

Relè d'avviamento

Start/stop switch

Start / stop schalter

Interruttore combinato d'avviamento e d'emergenza

Starter motor

Startermotor

Motorino d'avviamento

Tachometer

Drehzahlmesser

Contagiri

Temperature control lamp

Temperaturkontrolle

Controllo temperatura

Temperature sensor

Temperatursensor

Sensore temperatura

Temperature switch

Temperaturschalter

Interruttore termico

Throttle position sensor (TPS)

Vergaserpotentiometer

Potenziometro carburatore (sensore TPS)

CABLE COLOURS

KABELFARBEN

CAVO COLORATO

bl: black

bl: blau

bl: nero

br: brown

br: braun

br: marrone

bu: blue

bu: blau

bu: blu

gn: green

gn: grün

gn: verde

gr: grey

gr: grau

gr: grigio

or: orange

or: arancione

pi: pink

pi: rosa

pu: purple

pu: violett

pu: violetto

re: red

re: rot

re: rosso

wh: white

wh: weiß

wh: bianco

ye: yellow

ye: gelb

ye: giallo

Summary of Contents for 640 DUKE II 2005

Page 1: ...BEDIENUNGSANLEITUNG2005 OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 50 640 DUKE II...

Page 2: ...in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may...

Page 3: ...th an asterisk in the chapter Maintenance work on the chas sis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechani...

Page 4: ...warranty The fuels and lubricants specified in the owner s manual or those of an equal quality must be used in accordance with the maintenance schedule The warranty or guarantee shall become void for...

Page 5: ...age Correcting 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 lev...

Page 6: ...n lever 2 is 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 automat...

Page 7: ...indicator lamp flashes when the flasher light is working in the same rhythm as the flasher light Faster flashing of the flasher con trol lamp indicates a defect bulb The blue indicator lamp lights up...

Page 8: ...and should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position ignition ci...

Page 9: ...l have backup fuel next time too 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 s...

Page 10: ...degree of damping 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 clock...

Page 11: ...erse effect on the life of your engine WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST...

Page 12: ...the reservoir If the level of brake fluid falls below the min imum 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...

Page 13: ...TM dealer 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 CR...

Page 14: ...ITS STABILITY HIGH RPM 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 GIV ING IT A CHANCE TO W...

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

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

Page 17: ...em for function low high beams stop light turn indicators z z headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws a...

Page 18: ...MECHANIC before each start after every cleaning once a year Check oil level z Check brake fluid level z Check brake pads for wear z Check lighting system for proper operation z Check horn for proper o...

Page 19: ...RIVE TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED PROPERLY DISPO...

Page 20: ...uld now and 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 ridi...

Page 21: ...18 mm Preload with passenger 23 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 pr...

Page 22: ...CESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hexagon nuts on swing arm fists to 40 Nm 30 ft lb Tighten allan head screw 3...

Page 23: ...t once a year for maintenance 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...

Page 24: ...f the contact face 3 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 4 mm 0 016 in thinner than the pad s nom inal thickness Measure the nominal thickness...

Page 25: ...w the rim with clean brake fluid DOT 5 1 Motorex Brake Fluid 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water NEVER USE DOT 5 BRAKE FLUID IT IS BASED...

Page 26: ...brake fluid reservoir For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw 3 Then move the container outwards as indicated in the illus tration Remove plug 4 wi...

Page 27: ...ITH LOCTITE 243 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...

Page 28: ...d every time you want 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...

Page 29: ...ger period of standstill remove the battery and recharge it Storage temperature 0 35 C Do not expose to direct sun radiation Charging the battery NOTE A battery charger item no 58429074000 is availabl...

Page 30: ...the inside of the fuse 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 cons...

Page 31: ...H YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE HEAT WILL OTHER WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR Reconnect the cable plug Start the engi...

Page 32: ...thout fear of problems 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...

Page 33: ...remove air filter plus filter carrier from the filter box Thoroughly wash the air filter in special cleaning fluid and allow to dry well Motorex offers environmentally friendly products for professio...

Page 34: ...ecompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kick starter until the clicking sound disengaging of the automatic decompression...

Page 35: ...MABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY Engine oil Automobile engine oil used to be used for four stroke motorcycles before there were separate mot...

Page 36: ...t of the frame breast pipe see page 36 Replace the oil filter when changing the engine oil Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so th...

Page 37: ...ction piece and a plastic hose to the set of tools Take an empty oil can 1 liter and drill a 7 mm diameter hole into the lid Screw the hose connection piece into the lid from the outside and secure it...

Page 38: ...gap too large Spark plug connector or spark plug faulty The plug connection of the CDI unit the pulse generator or the ignition coil has oxydized Water in carburetor or jets blocked Open fuel tap tank...

Page 39: ...or leaking Air filter very dirty Valve clearance to small Loss of compression because hand decompressor has no play Electronic ignition timing faulty Clean and check fuel system as well as carburetor...

Page 40: ...il Blown fuse Replace fuse 2 The NEUTRAL lamp is not on even though the gear is in NEUTRAL Defect indicator lamp Defect neutral switch Loose connections defect cable Replace bulb Connect cable to grou...

Page 41: ...NIFICANTLY REDUCE THE BRAKING POWER AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL Should you desire to make a pause over a longer space of time please obs...

Page 42: ...dle bearing Top end bearing bronze bushing Piston forged aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication 2 Eaton Oilpumps Engine oil see table Q...

Page 43: ...ted 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 MTR 01 rea...

Page 44: ...ts rocker arm bolts M14x1 5 100 Nm Engine mounting screw M10 45 Nm Ball joint for push rod M8 Loctite 243 25 Nm Sprocket bolts with nuts M8 Loctite 243 35 Nm Collar nut swing arm bolt M14x1 5 100 Nm C...

Page 45: ...6 Draining of float chamber of the carburetor 34 Driving instructions 11 Emergency OFF tip switch light switch starter tip switch 7 Engine number engine type 5 Engine oil 34 Filler cap 7 Flasher repla...

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

Page 47: ...a l f 0 1 2 h c t i w s t h g i l e d o i d r a e r h c t i w s e k a r b ignition coil e d o i d d n 2 h t 3 N h c t i w s d n a t s e d i s r a e g h t 3 d n 2 r a e g h c t i w s l a r t u e n r e...

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

Page 49: ...tch 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 Contacteur de fr...

Page 50: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 01 2005 FOTO MITTERBAUER...

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