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ENGLISH

Engine oil

Use only synthetic oil brands (Motorex Power Synt
4T), that meet quality requirements of API-classes SG
or SH (information on bottles) or higher.

CAUTION

OOR OIL QUALITY OR LOW QUANTITY CAUSE EARLY ENGINE

WEAR

BASIC CARBURETOR SETTING

Carburetor

BST40-258

Main jet

145

Needle jet

689 X-6

Idling jet

Jet needle

6G5

Needle position from top

3 rd

Mixture.adju. screw open

2.25 turn

640 DUKE

40 kW

–

0°C

32°F

15W 40
15W 50

10W 40
10W 50

API: SG, SH

TEMPERATURE

TECHNICAL DATA – ENGINE 640 DUKE II 2003

Type

640 LC4

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter

Displacement

625 ccm

Bore / Stroke

101 / 78 mm

Ratio

11.5 : 1

Fuel

unleaded premium gasoline with a least RON 95

Valve timing

4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain

Camshaft

584-V03/1

Valve diameter

Intake: 36 mm Exhaust: 32 mm

Valve clearence cold

Intake: 0.15 mm Exhaust: 0.15 mm

Crank shaft bearing

2 cylinder roller bearing

Connecting rod bearing

needle bearing

Top end bearing

bronze bushing

Piston

forged aluminium alloy

Piston rings

1 compression ring, 1 taper face ring, 1 oil scraper ring

Engine lubrication

2 Eaton-Oilpumps

Quantity of engine oil

see table

Engine oil

2.1 liters including frame

Primary ratio

straight geared spur wheels 31 : 79 teeth

Clutch

multi-disc clutch in oil bath

Transmission

5-speed claw shifted

Gear ratio

1st 14:35

2nd 15:24
3nd 18:21

4th 20:19
5th 22:18

Ignition 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 DCPR 8E

Spark plug gap

0.9 mm

Cooling system

liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump

Cooling liquid

1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F)

Starting equipment

electric starter, kick starter

Содержание 640 DUKE II 2003

Страница 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art Nr 3 210 58 2 2003 640 DUKE II...

Страница 2: ...moval or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise...

Страница 3: ...and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM sh...

Страница 4: ...edule must be performed and service records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specifi...

Страница 5: ...ing chain tension 21 Chain maintenance 21 Chain wear 22 Maintaining chain tension eccentrics 22 General information about KTM disc brakes 23 Changing the basic position of the handbrake lever 24 Check...

Страница 6: ...only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the next attempt This is due to the fact that the automatic decompres...

Страница 7: ...when the flasher light is working in the same rhythm as the flasher light Faster flashing of the flasher control lamp indicates a defect bulb The blue indicator lamp lights up when the high beam is o...

Страница 8: ...switch has 3 positions Light off Parking light on Headlight on The emergency off switch 6 is provided for emergency situations and should not be used to switch off the engine The engine is ready for o...

Страница 9: ...uel next time too CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE Shift lever The shift le...

Страница 10: ...amping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far...

Страница 11: ...ith protective clothing and helmet Pay attention to running in instructions Running in Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a lon...

Страница 12: ...reservoir If the level of brake fluid falls below the mini mum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KT...

Страница 13: ...ler WARNING WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH IF THE ENGINE...

Страница 14: ...M RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FU...

Страница 15: ...is solid and that your motorcycle is standing securely Just in case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE THE SIDE STAND AND OR THE...

Страница 16: ...to the CDI box If the two connectors are connected to each other the ignition curve for fuel having at least 95 octane ROZ is activated If you disconnect the plug and socket connection the ignition cu...

Страница 17: ...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 adj...

Страница 18: ...gular intervals 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 chamb...

Страница 19: ...E YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PEN...

Страница 20: ...then be released a few turns to let overpressure if any escape from the interior of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motor...

Страница 21: ...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 22: ...INDLE BECOMES LOOSENED DURING THE PROCESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hexagon nuts on swing arm fists to 40 Nm...

Страница 23: ...ce them To do this Remove rear wheel Loosen hexagon nuts 1 on the left and right swing arm fists Remove eccentrics Clean eccentrics and swing arm fists thoroughly and grease the slide faces with a Mol...

Страница 24: ...l thickness Measure the nominal thickness in a location B outside the contact face Check wear in several locations WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SA...

Страница 25: ...DOT 5 1 Motorex Brake Fluid 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF...

Страница 26: ...r it is recommended to remove the hexagon screw 3 Then move the container outwards as indicated in the illustration Remove plug 4 with rubber boot 5 and add brake fluid DOT 5 1 Motorex Brake Fluid DOT...

Страница 27: ...TO PREVENT LOOSENING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE IT IS VERY IMPORTANT TO KEEP THE BRAKE D...

Страница 28: ...to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in your country for minimum t...

Страница 29: ...LL DESTROY THE RECTIFIER REGULATOR STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C Do not expose to direct sun rad...

Страница 30: ...use box The fuses marked RES are spare fuses Fuse 1 10 Ampere protects the following power consuming units ignition starter system Fuse 2 10 Ampere protects the following power consuming units flasher...

Страница 31: ...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 32: ...AUTION The red cooling liquid temperature warning light 5 will begin to light up if the cooling liquid temperature reaches approx 110 C and henceforth has exceeded its normal operating temperature Pos...

Страница 33: ...ir filter cover from the air filter box Unclap the filter holder 1 swing back and remove air filter plus filter carrier from the filter box Thoroughly wash the air filter in special cleaning fluid and...

Страница 34: ...WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Checking and adjusting the choke cable play The choke lever must always have a play of approx 4 mm 0 16 in CAUTION IF THERE IS NO PLAY IN THE CHOKE CABLE THE...

Страница 35: ...RM ANY WORK ON THE FUEL SYSTEM IN THE PRO XIMITY OF OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATU...

Страница 36: ...n 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 author...

Страница 37: ...escape turn off the engine and mount the plug together with the gasket Allow the engine to warm up check the engine oil level and correct if neces sary Afterwards check the entire oil system for leaka...

Страница 38: ...and emergency OFF switch contact a KTM dealer Replace fuse 1 Remove seat and replace the main fuse If fuse blows again contact a KTM dealer Contact a KTM dealer Contact a KTM dealer Open fuel tap tank...

Страница 39: ...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 40: ...gnition power consumer hasn t been 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...

Страница 41: ...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...

Страница 42: ...84 V03 1 Valve diameter Intake 36 mm Exhaust 32 mm Valve clearence cold Intake 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end beari...

Страница 43: ...el floated 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 rea...

Страница 44: ...1 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 bolts with nuts M8 Loctite 243 35 Nm 25ft lb Collar nut swing arm bolt M14x1 5...

Страница 45: ...chamber of the carburetor 34 Driving instructions 11 Engine number engine type 5 Engine oil 34 Filler cap 7 Flasher replacing the bulbs 30 Foot brake pedal 8 Fuel tap 8 Fuses 29 Page General informati...

Страница 46: ...ANHANG APPENDICE APPENDIX AP NDICE 1...

Страница 47: ...itch horn switch flasher switch 0 1 2 light switch diode rear brake switch ignition coil diode 2nd 3th N sidestand switch 3th gear 2nd gear neutral switch right front flasher front brake switch headli...

Страница 48: ...nterruttore folle Octane selector Oktananpassung Adattamento anticipo agli ottano Pick up Impulsgeber Pick up Rear brake switch Hinterer Bremslichtschalter Interruttore luce post di stop Rear light br...

Страница 49: ...ral switch Contacteur de point mort Interruptor de ralent Octane selector S lection pour l indice d octane Ajuste de octano Pick up Capteur d allumage Generador de impulsos Rear brake switch Contacteu...

Страница 50: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321058...

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