KTM DUKE 640 e Owner'S Handbook Manual Download Page 37

ENGLISH

35

Clean your motorcycle regularly in order to keep its painted finish looking shiny and new.
The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The hard
dirt can be removed before with the help of a soft water jet.

!

CAUTION

!

N

EVER CLEAN YOUR MOTORCYCLE WITH A HIGH

-

PRESSURED CLEANER OR A HIGH

-

PRESSURED WATER JET

. T

HE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS

CONNECTORS

SHEATHED CABLES

BEARINGS

CARBURETOR ETC

AND CAUSE DISTURBINGS OR LEAD TO A PREMATURE DESTRUC

-

TION OF THESE PARTS

.

– You should use normal trade-mark detergents to clean the engine. Strongly dirted parts should be cleaned additionally with the

help of a paint brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive

until the engine has reached the working temperature and also use the brakes. Due to the heat, the water also evaporates at the
unapproachable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate.

– After the motorcycle has cooled down, oil and grease all sliding and pivot points. Treat the chain with a chain spray too.
– Finally all painted parts should be treated with a gentle paint cleaner.
– To prevent failures in the electric system, you should treat the ignition lock, the emergency off switch, light switch and the socket

connectors with contact spray.

CLEANING

Should you desire to make a pause over a longer space of time, please observe the following instructions:
– Clean motorcycle thoroughly (see chapter: CLEANING)
– Change engine oil, oil filter and fine screen filter (old engine oil contains aggressive contaminations).
– Check antifreezer and amount of cooling liquid.
– Check antifreezer and cooling liquid level.
– Let the engine warm up again.
– Drain fuel from float chamber. By this means, carburetor jets are prevented from becoming resinous by the old fuel.
– Remove spark plug and fill in approx. 5 ccm of engine oil into the 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 (slowly operate the kickstarter, until you can hear the automatic decom-

pressor click (release))

– Let fuel flow out of tank into an appropriate container.
– Correct tire pressure.
– Lubricate pivot points of the control levers, foot rests, etc. as well as the chain.
– Servicing the shock absorber linkage and swing arm bearings.
– Remove and charge battery (see chapter: BATTERY).
– The storage place should be dry and not subject to excessive temperature fluctuations.
– Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use non air permeable materials as a possible humidity

might not be able to escape and could cause corrosion.

!

CAUTION

!

I

T IS EXTREMELY BAD TO LET THE ENGINE RUN FOR SHORT PERIODS OF TIME WHEN THE MOTORCYCLE IS KEPT IN STORAGE

. S

INCE IN THIS CASE THE ENGINE

WOULD NOT GET WARM ENOUGH

THE STEAM PRODUCED DURING THE COMBUSTION PROCESS WOULD CONDENSE AND CAUSE RUSTING ON CRANKSHAFT

,

MAIN BEARING

AND EXHAUST SYSTEM

.

RE-INITIATION AFTER TIME OF STORAGE:

– Mount the charged battery (regard polarity).
– Fill up tank with fresh fuel and turn the fuel tap to the ON position.
– Check motorcycle as before each start.
– Take a short, careful test ride first.

STORAGE

Summary of Contents for DUKE 640 e

Page 1: ...BEDIENUNGSANLEITUNG OWNER S HANDBOOK ART NR 3 205 41 2 98 Last Edition 1998 MANUEL D UTILISATION DUKE 640 e...

Page 2: ......

Page 3: ...FE ANYMORE Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the l...

Page 4: ...e to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform th...

Page 5: ...t disc brakes 20 Checking of brake fluid level front brake 20 Page Refilling the front brake fluid reservoir 21 Checking the front brake pads 21 Replacing front brake pads 21 Changing the basic positi...

Page 6: ...TCH WILL START TO SLIP THE CLUTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS Hand decompression lever The hand decompression lever 2 is only used in two special cases a When the engine stalled I...

Page 7: ...forward until only zeros can be seen in the display 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 CAUTION M...

Page 8: ...POSSIBLE The ignition key can be removed in the positions and Combination switch The rocker switch 1 actuates the high beam and low beam High beam light Low beam light The switch 2 returns to central...

Page 9: ...R USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher CAUTION USE ONLY UNLEADED PREMIUM GRADE...

Page 10: ...button back into its original position NOTE Always pull the hot start device back into the initial position as soon as the engine is running An activated hot start device will have a negative impact...

Page 11: ...ob 14 clicks counterclockwise Compression damping of shock absorber With the knob 3 the degree of damping of the compression can be adju sted to 7 positions Turn the knob counterclockwise to increase...

Page 12: ...met on rod turn key coun terclockwise as far as it goes WARNING NEVER LEAVE YOUR HELMET ATTACHED TO HELMET LOCK WHEN RIDING YOUR MOTORCYCLE BECAUSE THE HELMET CAN GET CAUGHT IN THE REAR WHEEL AND THRO...

Page 13: ...st 1000 KM 620 miles the engine oil used should be of a mineral oil formula This also applies if the engine has been repaired Check the following before each start When you start off the motorcycle mu...

Page 14: ...ights are on If this is not the case the battery is discharged and the engine can be started with the kickstarter see starting with an empty battery If the lights are on proceed as described in the Tr...

Page 15: ...G SYSTEM TROUBLE IMME DIATELY STOP AND TURN OFF THE ENGINE DRIVING WITH THE WAR NING LAMP ON WILL CAUSE ENGINE DAMAGE PLACE A CLOTH ON THE RADIATOR CAP OPEN THE CAP SLOWLY SO THE EXCESS PRESSURE IN TH...

Page 16: ...ER THE ENGINE ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up...

Page 17: ...f telescopic fork Check telescopic fork for leaks Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing c...

Page 18: ...UT BY A KTM DEALER CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPO...

Page 19: ...RIODS FIRSTLY THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED At least once a year the steering head bearings should be greased Changing the spring preload of the shock absorber...

Page 20: ...rely be pushed up to touch the swingarm at the level of the screw 2 see illustration If necessary correct chain tension WARNING IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY POWER TRANSMIS...

Page 21: ...the measurement at different pla ces on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets Maintaining chain tension ec...

Page 22: ...AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CHANGE BRAKE FLUID AT LEAST ONCE A YEAR IF THE MOTORCYCLE IS BEING WASHED VERY OFTEN CHANGE BRAKE FLUID MO...

Page 23: ...THAT THE LINING IS PARTLY OR ENTI RELY WORN AWAY THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC SIGNIFICANTLY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacin...

Page 24: ...TELY WORN DOWN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir When the brake fluid level has dropped to the MIN mark you need to refill the brake fl...

Page 25: ...the right fork leg axle passage leave the clamp screws on the left fork fist tightened Loosen wheel spindle 6 Hold the front wheel pull the wheel spindle out remove the front wheel from the fork by p...

Page 26: ...bsorp tion rubbers 2 to the rear wheel These 6 absorption rubbers wear with increasing operation time and should be checked for wear whenever the rear wheel is dismounted For this purpose lie the rear...

Page 27: ...1 located in the engine When the engine is cold the cooling liquid circulates only through the cylinder and the cylinder head After the engine has reached its operating temperature about 70 C 158 F th...

Page 28: ...NE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Fuse fan The fuse 1 for the fan is located behind the right radiator W...

Page 29: ...ID DAMAGE DO NOT REMOVE THE LOCKING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DEST ROY THE RECTIFIER REGULATOR STORAGE When preparing the motorcycle for a longer period...

Page 30: ...tightening the headlight mask the brown flasher cable is ground Finally check the electrical system for proper functioning Replacing the headlight bulb The headlights are accessible after you have re...

Page 31: ...ng speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly The throttle stop screw 3 is used to adjust the basic position of the slide Turning i...

Page 32: ...ment need be made to the automatic decompressor Oil circuit The oil pump 1 pumps the engine oil past the by pass valve 2 through the oil filter 3 After the oil filter an oil line branches off to a jet...

Page 33: ...of the oil system NOTE For improved cooling of the engine oil the front pipe of the frame is integrated into the oil circuit When changing the oil the engine oil must be drained from the front pipe T...

Page 34: ...s Remove oil filter cover 2 and oil filter Clean fil ter housing oil filter cover and sealing surfaces Check oil duct in oil filter cover if clogged Check the O ring 3 for damage O rings need not be r...

Page 35: ...itch on swing up side stand Starting see Driving Instrctions page13 Recharge the battery and investigate the causes for discharging contact a KTM dealer Check ignition lock and emergency OFF switch co...

Page 36: ...oat 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...

Page 37: ...he following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil oil filter and fine screen filter old engine oil contains aggressive contaminations Check antifreezer and a...

Page 38: ...2 psi 2 4 bar 35 psi Fuel tank capacity 11 3 liter 3 US gallons out of this 1 5 liter 0 42 US gallons reserve Final drive ratio 17 38 Chain o ring 5 8 x 1 4 Lamps low beam H1 12V 55W socket P14 5s HS1...

Page 39: ...gnition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max 38 BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DR8EA Spark plug gap 0 7 mm...

Page 40: ...2x1 5 30 Nm 22 ft lb Magnetic plug M12x1 5 20 Nm 15 ft lb Plug bypass valve M12x1 5 20 Nm 15 ft lb Hollow screws oil lines M8x1 10 Nm 7 4 ft lb Hollow screws oil lines M10x1 15 Nm 11 ft lb Jet screw c...

Page 41: ...ENGLISH 39 Notices...

Page 42: ...ENGLISH 40 Schaltplan...

Page 43: ...ENGLISH 41 Beschreibung Schaltplan...

Page 44: ...R T M O T O R C Y C L E A G A 5 2 3 0 M a t t i g h o f e n P o s t f a c h 9 1 A u s t r i a I n t e r n e t h t t p w w w k t m c o a t F N 1 0 2 0 1 9 d L a n d e s g e r i c h t R i e d i m I n n...

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