KTM 640 Duke Page 46 Owner'S Handbook Manual Download

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ENGLISH

Page

Adjusting idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Adjusting the choke cable . . . . . . . . . . . . . . . . . . . . . . .33

Adjusting the clutch cable . . . . . . . . . . . . . . . . . . . . . . .33

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

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

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

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

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

Change of oil and fine screen filter, bleeding of the oil system 35

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

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

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

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

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

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

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

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

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

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

Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .32

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

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

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

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

Checking the rubber ring on the shock absorber . . . . . .20

Checking the setting of the hand decompression cable .33

Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8

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

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

Consumer information for usa only . . . . . . . . . . .appendix

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 . . . . . . . . . . . . . . . . . . . . . .4

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

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

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

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

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fuses for indivitual power-consuming units . . . . . . . . . .29

Page

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

General tips and warnings for starting the motorcycle . .10

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .4

Head word index . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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

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

Ignition lock with 3 switch position . . . . . . . . . . . . . . . . .6

Ignition lock, with 4 switch position . . . . . . . . . . . . . . . .6

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

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

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

Lubricate rear shock absorber linkage . . . . . . . . . . . . . .20

Lubrication and maintenance schedule . . . . . . . . . . . . .16

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

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

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

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

Opening the head light mask . . . . . . . . . . . . . . . . . . . .29

Operation instruments . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .8

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

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

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

Re-initation after time of storage . . . . . . . . . . . . . . . . .40

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

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

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

Serial number locating . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

Shifting, Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

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

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

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

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

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

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

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

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Technical specifications - chassis . . . . . . . . . . . . . . . . . .42

Technical specifications - engine . . . . . . . . . . . . . . . . . .41

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

Page 1: ...Art Nr 3 210 23 12 2001 640 DUKE II OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG...

Page 2: ......

Page 3: ...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 control prior to its sale or...

Page 4: ...of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorc...

Page 5: ...1 Correcting chain tension 21 Chain maintenance 21 Page Chain wear 22 Maintaining chain tension eccentrics 22 General information about KTM disc brakes 23 Changing the basic position of the handbrake...

Page 6: ...cial 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 decompressor doesn t work prop...

Page 7: ...display Tachometer The tachometer 3 shows the engine speed in revolutions per minute rpm Do not push the engine into the orange zone which begins at 8500 rpm Indicator lamps The green indicator lamp...

Page 8: ...itions of ignition lock 2 Ignition off light off engine can t be started Ignition on light on engine can be started Ignition off light off handlebar blocked To switch the ignition to position turn the...

Page 9: ...the filler cap turn the ignition key 90 clockwise and take out the key Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON When using the motorcycle the twist g...

Page 10: ...ping rate of the compression damping mechanism can be readju sted at the adjusting screws 1 located at the fork leg Turn it clockwise to increase damping and counterclockwise to reduce damping during...

Page 11: ...during rcompressing STANDARD ADJUSTMENT WP 0118W719 position 3 Rebound damping of shock absorber With the setting wheel 2 the degree of damping of the rebound can be adjusted to 11 positions Turn the...

Page 12: ...nd 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 long time Therefore every en...

Page 13: ...rvoir 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 KTM spe...

Page 14: ...contact a KTM dealer 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 ENO...

Page 15: ...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 FURTHER PRECAUTIONS IN TH...

Page 16: ...E STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground is solid and that your motorcycle is standing securely Just in case you can s...

Page 17: ...ENGLISH 15...

Page 18: ...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 19: ...s in regular 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 floa...

Page 20: ...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 21: ...greased Bleeder screw front fork The bleeder screws 3 should 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...

Page 22: ...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 23: ...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 24: ...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 25: ...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 nominal thickness Measure the nominal thickness in a location B out...

Page 26: ...Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 Replace membrane and lid t...

Page 27: ...uid reservoir When the brake fluid level has dropped to the MIN mark you need to refill the brake fluid reservoir For easier access to the brake fluid reservoir it is recommended to remove the hexagon...

Page 28: ...clamp screws on the right fork leg axle passage to 10 Nm 7 ft lb WARNING THE AH SCREWS 1 OF THE BRAKE CALIPER MUST BE SECURED WITH LOCTITE 243 TO PREVENT LOOSENING IF YOU DON T HAPPEN TO HAVE A TORQUE...

Page 29: ...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 30: ...DO 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 standsti...

Page 31: ...g 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 brake light horn...

Page 32: ...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 33: ...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 34: ...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 35: ...he counter nut and correct the adjusting screw 3 accor dingly Tighten counter nut and push back protective cover CAUTION THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED SEE MAI...

Page 36: ...L WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY Engine oil Only use synthet...

Page 37: ...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 auth...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...e 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 Connecting rod bearing needle bearing...

Page 44: ...bon steel 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...

Page 45: ...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 46: ...e number engine type 4 Engine oil 34 Filler cap 7 Flasher replacing the bulbs 30 Foot brake pedal 8 Fuel 14 Fuel tap 7 Fuses for indivitual power consuming units 29 Page General information about KTM...

Page 47: ...ANHANG APPENDICE APPENDIX AP NDICE 1...

Page 48: ...ANHANG APPENDICE APPENDIX AP NDICE 2...

Page 49: ...ANHANG APPENDICE APPENDIX AP NDICE 3...

Page 50: ...ING THEREOF 1 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 t...

Page 51: ...ANHANG APPENDICE APPENDIX AP NDICE 5 K T M 6 4 0 D U K E I I 2 0 0 2 U S A left side right side...

Page 52: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321023...

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KTM 640 Duke, Owner'S Handbook Manual

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