KTM 640 Duke, Owner'S Handbook Manual, Page: 37 / 52

ENGLISH
35
Oil circuit
The oil pump
1
pumps the motor oil past the bypass valve
2
and through
the oil filter
3
. Beyond the oil filter, one of the oil lines forks off to a jet
4
that injects motor oil to the piston pin bearing and the piston head. The
second oil line leads the main oil flow to the frame breast pipe
5
where the
motor oil is cooled off. Then the motor oil flows through the fine screen fil-
ter
6
that removes even the finest of contaminants from the motor oil. The
cleansed motor oil is pumped via an oil line and the clutch cover into the
crankshaft to the conrod bearing
7
and drains from there into the crank
case. A additional oil pump
8
suctions the motor oil out of the crank case
and pumps it through the oil canal
9
to the gear wheels of the 4th and 5th
gears. The motor oil reaches the oil sump via the gear wheels. The timing
chain
bk
also dips into the oil sump and propels motor oil upwards to the
cylinder head. The motor oil reaches the camshaft
bm
and the valves
through the bore
bl
.
Oil and screen filter change, bleeding of the oil system *
Note: The frame breast pipe is integrated into the oil circuit for the sake of
more effectively cooling the motor oil. It is thus important when changing
the oil to also remove the fine screen filter, to drain the motor oil from the
breast pipe and to de-aerate the oil system.
If the oil system is not bled at all or bled insufficiently, the bearings 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 guaranty period, the oil change must
be performed by an authorized KTM mechanic. Otherwise, the guarantee
will become void.
The engine oil change is to be carried out when the engine is still warm.
WARNING
A
N ENGINE HAVING BEEN RUN WARM
,
AND THE ENGINE OIL IN IT IS VERY HOT
-
DO NOT
BURN YOURSELF
.
Place the motorcycle on a horizontal surface. Remove the two plugs bn and
bo , and drain oil into a container.
!
CAUTION
!
P
LUG
A
MUST NOT BE REMOVED
,
THIS IS PART OF THE BY
-
PASS VALVE
.
Remove the screws and the cover
bp
. Loosen the fine screen filter
6
with
an oil filter wrench and then screw it off by hand.
The screw bq must be removed to allow the motor oil to flow out of the
frame breast pipe.
Clean the plugs thoroughly with petroleum and compressed air in order to
remove any metal filings. After the oil has drained completely, clean the
sealing areas and remount the plugs together with their gaskets. Tighten
plug
bn with 30 Nm and plug bo with 20 Nm. Tighten the screw bq with
10 Nm. Clean sealing surfaces on the frame breast pipe br , fill new fine
screen filter with engine oil, and oil rubber gasket bs . Replace fine screen fil-
ter and screw it back in place, your bare hand will do.
Remove oil dipstick on the clutch cover, fill with 1,3 litre engine oil and
attach plug again.
!
CAUTION
!
– U
SE ONLY ORIGINAL
KTM
FINE SCREEN FILTERS
. U
SING ANOTHER FILTER BRAND CAN
RESULT IN DAMAGE TO THE ENGINE
.
– I
F THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME
,
YOU
MUST BLEED THE OIL SYSTEM
!
A
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