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ENGLISH

30

Engine oil

Only use synthetic high-quality oils (Shell Advance Ultra 4) meeting or sur-
passing the quality requirements of API classes SG, or SH (for specifications
see containers).

!

CAUTION

!

I

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE

.

Checking the engine oil level

Allow the engine to run at idle speed for about 4 minutes. Turn off the
engine and place the motorcycle on a flat, level surface (center stand). Wait
5 minutes, unscrew and remove the oil dipstick 

1

, and wipe it clean with 

a cloth.
SCREW THE DIPSTICK IN ALL THE WAY AND REMOVE IT AGAIN.
The oil level should be between the two marks on the dipstick, however, it
must never rise above the MAX mark. Otherwise, engine oil would get into
the air filter box by way of the engine venting system.
Add engine oil if necessary.

!

CAUTION

!

– I

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE

ENGINE

.

– C

HECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE

READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL

.

– D

O NOT OVERFILL THE ENGINE CASE

.

– D

O NOT UNDERFILL THE ENGINE CASE

.

Finally, check oil system and engine for leaks.

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 

2

and

3

, 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 

4

. Loosen the fine screen filter 

5

with

an oil filter wrench and then screw it off by hand.

The screw 

6

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 

2

with 30 Nm and plug 

3

with 20 Nm. Tighten the screw 

6

with 

10 Nm. Clean sealing surfaces on the frame breast pipe 

7

, fill new fine

screen filter with engine oil, and oil rubber gasket 

8

. 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

!

                   

+

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API:  SG, SH

TEMPERATURE

1

MAX

MIN

A

2

3

4

5

6

7

8

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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