ENGLISH
34
TROUBLE
Engine does not rev high
Engine will not reach full
power
Engine misfires or backfires
into carburetor
Engine overheats
High oil consumption
All switched on lamps blown out
The neutral lamp is not on
even though the gear is in
neutral
The battery is discharged
CAUSE
Carburetor fuel level too high because
– Float needle is dirty or worn out
– Float leaks
– Float has no axial play
Loose carburettor jets
Electronic ignition timing faulty
Fuel supply partically interrupted or
carburetor dirty
Float leaks, or no axial play
Air filter very dirty
Exhaust system leaking or deformed
Valve clearance to small
Loss of compression because hand
decompressor has no play
Electronic ignition timing faulty
Fuel shortage
Engine takes in unmetered air
Insufficient cooling liquid
Radiator fins are extremely dirty
Foam forms in cooling system
Bent radiator hose
Thermostat defective
Blown fan fuse
Defect thermoswitch
Fan defective
Buckling gear ventilation hose
Engine oil level too high
Engine oil too thin (viscosity)
Voltage regulator faulty
Defect indicator lamp.
Defect neutral switch.
Loose connections, defect cable.
The ignition (power consumer)
hasn’t been switched off
The battery isn’t charged by the
generator because
REMEDY
Dismount carburetor and check if worn out
Replace float needle
Replace float
Abrade float
Tighten jets
Have ignition system checked
Clean and check fuel system as well as carburetor
Replace or abrade the float
Clean or replace air filter, contact a KTM dealer
Check if exhaust system is damaged
Have valve clearance adjusted
Check setting of the hand decompression cable
Have ignition system checked
Clean and check fuel system and carburettor
Check intake flange and carburettor for tight fit
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Clean radiator with water jet
Replace cooling liquid, use antifreezer with brand name
Shorten or replace cooling hose
Remove and check thermostat (opening temperature 70°C
(158°F) or replace it, contact a KTM dealer
Replace fuse and check if fan operates properly (see below)
Contact a KTM dealer
Check if fan operates properly. To do this, start the engine,
then bypass the connections to the thermoswitch (bottom
right radiator), contact a KTM dealer
Readjust or replace ventilation hose
Check engine oil level when the engine is warm; correct if necessary
Use thicker engine oil; see chapter „Engine oil“
Remove seat and check connections. Have voltage regulator checked
Replace indicator lamp
Connect cable to ground; neutral switch must be replaced if
indicator lamp lights up.
Check connections and cables.
Recharge the battery according to the relevant instructions.
Remove seat and check voltage regulator connections; vol-
tage regulator and generator should be checked by a KTM
dealer.
Summary of Contents for DUKE 640 e
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Page 41: ...ENGLISH 39 Notices...
Page 42: ...ENGLISH 40 Schaltplan...
