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ENGLISH

12

Kickstart instructions

Go to the left of your motorbike. DO NOT open the throttle,
and briskly kick the kickstarter ALL THE WAY.

WARNING

– I

F YOU WANT TO START THE ENGINE

MAKE SURE THAT YOU ALWAYS

PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

.

Y

OU MIGHT SLIP OFF THE KICKSTARTER

OR THE ENGINE MAY KICK

BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE

.

– A

LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING

THE THROTTLE

. K

ICKING THE KICKSTARTER WITH NOT ENOUGH

MOMENTUM

AND AN OPENED THROTTLE GRIP INCREASE THE KICK

-

BACK HAZARD

.

!

CAUTION

!

D

ON

T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON

T REV

ENGINE WHEN COLD

. B

ECAUSE THE PISTON IS WARMING UP FASTER THAN

THE WATER COOLED CYLINDER

IT CAN CAUSE ENGINE DAMAGE

.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly
release the clutch lever and open throttle at the same time.

WARNING

B

EFORE YOU START OFF

CHECK THAT THE SIDE STAND HAS BEEN SWUNG

RIGHT UP TO THE TOP

. I

F THE STAND DRAGS ON THE GROUND

THE

MOTORCYCLE CAN GO OUT OF CONTROL

.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption. 
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to NEUTRAL.

WARNING

– O

BSERVE THE TRAFFIC REGULATIONS

DRIVE DEFENSIVELY AND TRYING

TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE

.

– A

DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

– D

RIVE CAREFULLY ON UNKNOWN ROADS

– A

VOID ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY

ROADS

. O

THERWISE

THE MOTORCYCLE COULD EASILY GET OUT OF

CONTROL

.

– N

EVER TURN THE IGNITION KEY TO POSITION

OR

WHILE THE

MOTORCYCLE IS MOVING

.

– R

EPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY

OF TIME

. W

HEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

GOGGLES

YOU WILL BE PRACTICALLY BLIND

.

– A

FTER FALLING WITH THE MOTORCYCLE

CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

– A 

BENT HANDLEBAR MUST ALWAYS BE REPLACED

. N

EVER TRY TO

STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS
STABILITY

.

!

CAUTION

!

– H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. W

E RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP

. A

FTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

.

– S

HIFT TO THE NEXT HIGHER GEAR BY

8500 

RPM AT THE LATEST

.

E

NGINE SPEEDS IN THE RED RANGE MUST STRICTLY BE AVOIDED

.

– N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A

LOWER GEAR

. T

HE ENGINE WILL OVERSPEED

DAMAGING THE VALVES

.

I

N ADDITION

THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

.

– L

ONG WHEELIE DRIVING CAUSES THE OIL PRESSURE TO DROP

. T

HE OIL

PRESSURE WILL AUTOMATICALLY INCREASE AS SOON AS YOU DRIVE ON
NORMALLY

. D

OING WHEELIES FOR A LONG TIME WILL DAMAGE YOUR

ENGINE

.

– I

F THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE

YOU ARE DRIVING

THIS INDICATES COOLING SYSTEM TROUBLE

. I

MME

-

DIATELY STOP AND TURN OFF THE ENGINE

. D

RIVING WITH THE WAR

-

NING LAMP ON WILL CAUSE ENGINE DAMAGE

.

– P

LACE A CLOTH ON THE RADIATOR CAP

. O

PEN THE CAP SLOWLY

,

SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE

. -

CAUTION SCALDING HAZARD! - 

AND CHECK THE COOLING

LIQUID LEVEL

.

– D

O NOT DRIVE ON

UNTIL THERE IS SUFFICIENT LIQUID IN THE COO

-

LING SYSTEM

. H

OWEVER

CALL ON ONE OF

KTM’

S DEALERS AS

SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED

– I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING

CHECK THAT

THE ENGINE FASTENING SCREWS ARE TIGHT

.

– I

N THE EVENT THAT

WHILE RIDING YOUR MOTORCYCLE

YOU NOTICE

ANY UNUSUAL OPERATION

-

RELATED NOISE

STOP IMMEDIATELY

TURN

THE ENGINE OFF

AND CONTACT AN AUTHORIZED

KTM 

DEALER

.

Braking

Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving downhill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

– D

ELAYED BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS

DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE

.

I

N THIS CASE

REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY

.

– D

ELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY

ROADS

. I

N THIS CASE

REPEATEDLY APPLY THE BRAKES TO REMOVE THE

DIRT

.

– W

HEN YOU BRAKE

THE BRAKE DISCS

BRAKE PADS

BRAKE CALIPER

AND BRAKE FLUID HEAT UP

. T

HE HOTTER THESE PARTS GET

THE WEA

-

KER THE BRAKING EFFECT

. I

N EXTREME CASES

THE ENTIRE BRAKING

SYSTEM CAN FAIL

.

Содержание 640 DUKE II 2001

Страница 1: ...OWNERS HANDBOOK 2001 BEDIENUNGSANLEITUNG 640 DUKE II Art Nr 3 205 99 11 2000...

Страница 2: ......

Страница 3: ...a 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 the pur pose...

Страница 4: ...over to the new owner Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this Owner s Handbook to carry out most of the maint...

Страница 5: ...level front brake 20 Refilling the front brake fluid reservoir 20 Checking the front brake pads 21 Changing the basic position of the brake pedal 21 Checking the rear brake fluid level 21 Refilling th...

Страница 6: ...This is due to the fact that the automatic decompressor doesn t work properly If this happens pull the manual decompression lever and start again Afterwards normal starting will be possible b When yo...

Страница 7: ...AXIMUM RECOMMENDED ROTATION RATE IS 8500 RPM ROTATION RATES EXCEEDING 8500 RPM WILL SHORTEN YOUR ENGINE S LIFE REFER ALSO TO THE SECTION ON RUN NING IN YOUR MOTORCYCLE TO BE FOUND IN THE DRIVING INSTR...

Страница 8: ...to position and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Combination switch Th...

Страница 9: ...AUSE IT MAY DAMAGE THE ENGINE WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETT...

Страница 10: ...METHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Compression damping of fork Hydraulic compression damping de...

Страница 11: ...D BE THE RESULT Seat lock The seat is secured by the lock on the side of the seat 3 REMOVING THE SEAT Put the ignition key into the lock Turn it counter clockwise all the way to the stop to unlock the...

Страница 12: ...in the tachometer Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine Check the following before each start...

Страница 13: ...t is on ignition lock in position If this is not the case the battery is discharged If the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer WARNING WHEN START...

Страница 14: ...ES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A BENT HANDLEBAR MUST ALWAYS BE REPLACED NEVER TRY TO STRAIGHTEN T...

Страница 15: ...Y GRASS OR OTHER EASILY FLAMMABLE MATERIALS CAUTION PARK YOUR MOTORCYCLE SO THAT IT RESTS STABLY ON THE SIDE STAND HARD GROUND LEVEL SURFACE AND CAN T TIP OVER CLOSE THE FUEL TAP WHEN LEAVING YOUR VEH...

Страница 16: ...l 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 ad...

Страница 17: ...als 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 float chamber Verify sm...

Страница 18: ...hould be greased WARNING MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM D...

Страница 19: ...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...

Страница 20: ...move upwards CAUTION IF THE WHEEL SPINDLE BECOMES LOOSENED DURING THE PROCESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hex...

Страница 21: ...AS POSSIBLE CAUTION IF THE ECCENTRICS ARE NOT ALIGNED THE REAR WHEEL WILL REST AT AN ANGLE IN THE SWING ARM THIS WILL STRESS THE REAR WHEEL AND SWING ARM BEARINGS AND DAMAGE THEM IF NOT CORRECTED Gene...

Страница 22: ...S BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY CHANGE BRAKE FLUID AT LEAST ONCE A YEAR IF THE MO...

Страница 23: ...uretor connection boot The brake fluid level may not drop below the MlN marking when the vehicle is in an upright position WARNING IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYS...

Страница 24: ...e speedometer drive To mount the front wheel insert speedometer drive into the front wheel Lift the front wheel into the fork and position the speedometer drive as shown in the illustration the connec...

Страница 25: ...re the tires have in them affect the way your motorcycle rides and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle Tire type and size can be found in the...

Страница 26: ...O 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 standstil...

Страница 27: ...to Exchanging 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 brak...

Страница 28: ...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...

Страница 29: ...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...

Страница 30: ...ut 1 accordingly Checking the adjustment of the hand decompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kick starter until the cli...

Страница 31: ...BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL...

Страница 32: ...gs 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 guara...

Страница 33: ...e oil would get into the air filter box by way of the engine venting system Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING TH...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...inder 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 slow...

Страница 38: ...camshaft camshaft drive through single 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...

Страница 39: ...el 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 160 60...

Страница 40: ...r arm bolts M14x1 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 screws on nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swingarm...

Страница 41: ...TRUCTIONS 10 Emergency OFF button 6 Emergency OFF switch Australia 7 Engine number engine type 4 Engine oil 30 Filler cap 7 Flasher replacing the bulbs 26 Foot brake pedal 8 Page Fuel 7 Fuel tap 7 Fus...

Страница 42: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 320599...

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