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ENGLISH

TROUBLE SHOOTING

TROUBLE

CAUSE

REMEDY

Engine fails to idle

Glogged idling jet

Oncorrect adjustment of adjusting

screws on carburetor

Defective spark plug

Defective ignition system

Disassemble carburetor and clean jets

Have carburetor adjusted

Replace spark plug

Have ignition system checked

Engine does not rev high

Carburetor fuel level too high

because

Float needle is dirty or worn out

Float leaks

The cold starting system is perma-

nently activated due to a lack of

play in the choke cable.

Defective membrane of slide

Carburetor leaking

Loose carburettor jets

Electronic ignition timing faulty

Dismount carburetor and check if worn out

Replace float needle

Replace float

Adjust choke cable.

Replace membrane

Check vacuum hose and venting hoses of carburetor for cor-

rect position (no kinks)

Tighten jets

Have ignition system checked

Engine will not reach full

power

Fuel supply partically interrupted

or carburetor dirty

Float leaks

Defective membrane of slide

Carburetor leaking

Air filter very dirty

Valve clearance to small

Loss of compression because

hand decompressor has no play

Electronic ignition timing faulty

Clean and check fuel system as well as carburetor

Replace the float

Replace membrane

Check vacuum hose and venting hoses of carburetor for cor-

rect position (no kinks)

Clean or replace air filter, contact a KTM dealer

Have valve clearance adjusted

Check setting of the hand decompression cable

Have ignition system checked

Engine overheats

Insufficient cooling liquid

Radiator fins are extremely dirty

Foam forms in cooling system

Bent radiator hose

Thermostat defective

Blown fan fuse

Defect thermoswitch

Fan defective

Refill cooling liquid (see maintenace work), check cooling

system for leaks

Clean radiator with water jet

Replace cooling liquid, use antifreezer with brand name

Shorten or replace cooling hose

Remove and check thermostat (opening temperature 70°C

(158°F) or replace it, contact a KTM dealer

Replace fuse and check if fan operates properly (see below)

Contact a KTM dealer

Check if fan operates properly. To do this, start the engine,

then bypass the connections to the thermoswitch (bottom

right radiator), contact a KTM dealer

Содержание 640 DUKE II 2005

Страница 1: ...BEDIENUNGSANLEITUNG2005 OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 50 640 DUKE II...

Страница 2: ...in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may...

Страница 3: ...th an asterisk in the chapter Maintenance work on the chas sis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechani...

Страница 4: ...warranty The fuels and lubricants specified in the owner s manual or those of an equal quality must be used in accordance with the maintenance schedule The warranty or guarantee shall become void for...

Страница 5: ...age Correcting 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 lev...

Страница 6: ...n lever 2 is 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 automat...

Страница 7: ...indicator lamp flashes when the flasher light is working in the same rhythm as the flasher light Faster flashing of the flasher con trol lamp indicates a defect bulb The blue indicator lamp lights up...

Страница 8: ...and should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position ignition ci...

Страница 9: ...l have backup fuel next time too 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 s...

Страница 10: ...degree of damping 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 clock...

Страница 11: ...erse effect on the life of your engine WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST...

Страница 12: ...the reservoir If the level of brake fluid falls below the min imum 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...

Страница 13: ...TM dealer 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 CR...

Страница 14: ...ITS STABILITY HIGH RPM 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 GIV ING IT A CHANCE TO W...

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

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

Страница 17: ...em for function low high beams stop light turn indicators z z headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all screws a...

Страница 18: ...MECHANIC before each start after every cleaning once a year Check oil level z Check brake fluid level z Check brake pads for wear z Check lighting system for proper operation z Check horn for proper o...

Страница 19: ...RIVE TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED PROPERLY DISPO...

Страница 20: ...uld now and 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 ridi...

Страница 21: ...18 mm Preload with passenger 23 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 pr...

Страница 22: ...CESS RETURN ECCENTRICS TO THEIR ORIGINAL POSITION BEFORE RETIGHTENING THE WHEEL SPINDEL SEE MAINTAINING ECCENTRICS Tighten hexagon nuts on swing arm fists to 40 Nm 30 ft lb Tighten allan head screw 3...

Страница 23: ...t once a year for maintenance 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...

Страница 24: ...f the contact face 3 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 4 mm 0 016 in thinner than the pad s nom inal thickness Measure the nominal thickness...

Страница 25: ...w the rim with clean brake fluid DOT 5 1 Motorex Brake Fluid 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water NEVER USE DOT 5 BRAKE FLUID IT IS BASED...

Страница 26: ...brake fluid reservoir For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw 3 Then move the container outwards as indicated in the illus tration Remove plug 4 wi...

Страница 27: ...ITH LOCTITE 243 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...

Страница 28: ...d every time you want 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...

Страница 29: ...ger period of standstill remove the battery and recharge it Storage temperature 0 35 C Do not expose to direct sun radiation Charging the battery NOTE A battery charger item no 58429074000 is availabl...

Страница 30: ...the inside of the fuse 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 cons...

Страница 31: ...H YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE HEAT WILL OTHER WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR Reconnect the cable plug Start the engi...

Страница 32: ...thout fear of problems 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...

Страница 33: ...remove air filter plus filter carrier from the filter box Thoroughly wash the air filter in special cleaning fluid and allow to dry well Motorex offers environmentally friendly products for professio...

Страница 34: ...ecompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kick starter until the clicking sound disengaging of the automatic decompression...

Страница 35: ...MABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY Engine oil Automobile engine oil used to be used for four stroke motorcycles before there were separate mot...

Страница 36: ...t of the frame breast pipe see page 36 Replace the oil filter when changing the engine oil Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so th...

Страница 37: ...ction piece and a plastic hose to the set of tools Take an empty oil can 1 liter and drill a 7 mm diameter hole into the lid Screw the hose connection piece into the lid from the outside and secure it...

Страница 38: ...gap too large Spark plug connector or spark plug faulty The plug connection of the CDI unit the pulse generator or the ignition coil has oxydized Water in carburetor or jets blocked Open fuel tap tank...

Страница 39: ...or leaking Air filter very dirty Valve clearance to small Loss of compression because hand decompressor has no play Electronic ignition timing faulty Clean and check fuel system as well as carburetor...

Страница 40: ...il Blown fuse Replace fuse 2 The NEUTRAL lamp is not on even though the gear is in NEUTRAL Defect indicator lamp Defect neutral switch Loose connections defect cable Replace bulb Connect cable to grou...

Страница 41: ...NIFICANTLY REDUCE THE BRAKING POWER AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL Should you desire to make a pause over a longer space of time please obs...

Страница 42: ...dle 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 Engine oil see table Q...

Страница 43: ...ted 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 MTR 01 rea...

Страница 44: ...ts rocker arm bolts M14x1 5 100 Nm Engine mounting screw M10 45 Nm Ball joint for push rod M8 Loctite 243 25 Nm Sprocket bolts with nuts M8 Loctite 243 35 Nm Collar nut swing arm bolt M14x1 5 100 Nm C...

Страница 45: ...6 Draining of float chamber of the carburetor 34 Driving instructions 11 Emergency OFF tip switch light switch starter tip switch 7 Engine number engine type 5 Engine oil 34 Filler cap 7 Flasher repla...

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

Страница 47: ...a l f 0 1 2 h c t i w s t h g i l e d o i d r a e r h c t i w s e k a r b ignition coil e d o i d d n 2 h t 3 N h c t i w s d n a t s e d i s r a e g h t 3 d n 2 r a e g h c t i w s l a r t u e n r e...

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

Страница 49: ...tch 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 Contacteur de fr...

Страница 50: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 01 2005 FOTO MITTERBAUER...

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