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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.

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CAUTION

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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.

– Befor cleaning with water, plug the exhaust pipe to prevent water ingress
– 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.
– Warm up the engine once again, close the fuel tap and wait until the engine dies. Then open the drain plug of the float chamber to

remove the remaining 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.

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CAUTION

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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.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any ser-
vice jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics’
shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

STORAGE

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take 
precautions against the aggressive road salt.
– clean motorcycle thoroughly and let it dry
– treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion

agent.

WARNING

K

EEP ANTI

-

CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS

FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING

POWER

.

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CAUTION

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A

FTER RIDES ON SALTED ROADS

CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL

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CONSERVATION FOR WINTER OPERATION

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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