Related Manuals for KTM DUKE 640 e
Summary of Contents for KTM DUKE 640 e
- Page 1 D U K E 6 4 0 e Last Edition 1998 BEDIENUNGSANLEITUNG O W N E R ’ S H A N D B O O K MANUEL D’UTILISATION ART. NR. 3.205.41 2.98...
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Page 3: Important Notes
IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS HANDBOOK CAREFULLY AND COMPLETELY BEFORE YOU TAKE YOUR FIRST RIDE. IT CONTAINS INFORMATION AND TIPS THAT WILL BE ABLE YOU TO OPERATE AND HANDLE YOUR MOTORCYCLE PROPERLY. PAY ATTENTION ESPECIALLY TO THE FOLLOWING INSTRUCTIONS: WARNING IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE. - Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now owner of a sporty and modern motorcycle which you are bound to have a great time with, provided you care for it properly. This manual will furnish you with important information on how to operate and maintain your new KTM motorcycle.
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Page 5: Table Of Contents
INDEX Page Page IMPORTANT NOTES ......1 Refilling the front brake fluid reservoir ... . .21 Checking the front brake pads . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Frame number The frame number is stamped on the right side of the steering head tube. Write this number into the relevant box on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the engine sprocket. -
Page 7: Choke Lever
Choke lever When the choke lever is pulled backwards, a bore is opened in the car- buretor which enables the engine to draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. When the choke lever is pushed forward as far as it will go, the bore will be closed again. -
Page 8: Ignition Lock, Steering Lock
Ignition lock, steering lock There are four positions to this lock. They are: = ignition off, light off = ignition on, – engine turned off: just parking light is on – engine running: parking light and headlight on = ignition off, light off, handlebar locked CAUTION RIEFLY PRESS THE KEY IN THE POSITION IN ORDER TO TURN THE IGNITION... -
Page 9: Headlight Range Adjustment
Headlight range adjustment The headlight beam must be adjusted to the current load (i.e. with/without passenger). The adjustment can be performed very easily by means of the setting wheel on the cockpit. Turn clockwise to reduce the range of the headlights. Turn counterclockwise to increase the range of the headlights. -
Page 10: Fuel Tap
Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx. -
Page 11: Compression Damping Of Fork
Compression damping of fork The compression damping „COM“ (Compression) is mounted in the right fork tube. It only regulates the degree of damping during compressing. With the knob the degree of damping of the compression can be adju- sted. Turn the knob clockwise to increase damping, turn it counterclock- wise to reduce damping during compressing. -
Page 12: Helmet Lock
Helmet lock The helmet lock is located behind the right side cover. To unlock it, ins- ert ignition key and turn it clockwise. Hang helmet on rod, turn key coun- terclockwise as far as it goes. WARNING EVER LEAVE YOUR HELMET ATTACHED TO HELMET LOCK WHEN RIDING YOUR MOTORCYCLE BECAUSE THE HELMET CAN GET CAUGHT IN THE REAR WHEEL AND THROW THE VEHICLE OUT OF CONTROL Passenger handles... -
Page 13: Driving Instructions
Arrange for the braking system to be checked by a KTM Never exceed the maximum permissible laden weight and specialist garage, as complete failure of the braking system the axle weights. - Page 14 – If this is not the case, refill the tank – if sufficient fuel is in the tank, proceed as described in the „Trouble- shooting“ section or contact a KTM dealer. THE ELECTRIC STARTER DOESN’T CRANK THE ENGINE WHEN THE...
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Page 15: Kickstart Instructions
MOTORCYCLE CAN GO OUT OF CONTROL LIQUID LEVEL – D O NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COO KTM’ LING SYSTEM OWEVER CALL ON ONE OF S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED –... - Page 16 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.
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Page 17: Lubrication And Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE rider dealer Duke 2.98 IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks... -
Page 18: Maintenance Work On Chassis And Engine
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNO- WLEDGE. FOR YOUR OWN SAFETY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER CAUTION – W HEN CLEANING THE MOTORCYCLE... -
Page 19: Checking And Adjusting The Steering Head Bearing
At least once a year, the steering head bearings should be greased. Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only, weighing approximately 75 kg (165 lb). If you want to take a passenger with you, of if you weigh con- siderably more or less than 75 kg (165 lb), you should change the spring preload accordingly. -
Page 20: Checking The Rubber Ring On The Shock Absorber
Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm wide. Have the rub- ber ring replaced in a KTM garage when compaction due to wear has exceeded the limit. -
Page 21: Chain Maintenance
Chain maintenance O-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special O-ring chain spray (i.e. Shell Advance Bio Chain). WARNING O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHER... -
Page 22: General Information About Disc Brakes
(eg. too much give , i.e. “spongy” resistance), refrain immediately from using your motorcycle. Take it to a KTM dealer and have the problem taken care of by experts. WARNING – H... -
Page 23: Refilling The Front Brake Fluid Reservoir
Refilling the front brake fluid reservoir* When the brake fluid falls to the middle of the inspection glass, new brake fluid has to be added. Loosen screws and remove lid and membrane Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm below the rim with brake fluid (DOT 5.1). -
Page 24: Changing The Basic Position Of The Brake Pedal
Changing the basic position of the brake pedal* The basic setting of the foot brake pedal can be changed by turning the stop roller . Using the piston rod , the free play on the foot brake pedal must be set. In order to be able to turn the piston rod, the counter nut must first be loosened. -
Page 25: Dismounting And Mounting The Front Wheel
Remove cotter pin , knock out the cotter bolt from the brake caliper with an insert stake towards the chain wheel and remove brake pads. Carefully clean the brake caliper with compressed air and check sleeves of the guide pins for damage. Slide right brake pad into the brake caliper and fix it with the bolt. -
Page 26: Dismounting And Mounting The Rear Wheel
Dismounting and mounting the rear wheel* – Jack the motorcycle up by the frame so that the rear wheel no longer touches the ground. – Loosen the wheel spindle – Holding the rear wheel, remove wheel spindle. – Pull down on the rear wheel, pushing it slightly forward and lift the chain from the chain wheel. -
Page 27: Checking Spoke Tension
(see illustra- tion). A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. -
Page 28: Cooling Liquid Level Check
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it ins- pected by a KTM dealer. CAUTION NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE “... -
Page 29: Battery
Battery The battery is mounted under the seat (remove the seat, see page 16) The battery has a closed system and therefore requires no maintenance. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. -
Page 30: Removing The Headlight Mask
Removing the headlight mask* The headlight mask must be removed whenever you want to change the headlight or instrument lamps. a) Removing the front flashers. – Remove the lens by inserting a screw driver in the lateral slot to separate the lens from the flasher housing. –... -
Page 31: Cleaning The Air Filter
, swing it backwards and take air filter and filter support out of the filter box. CAUTION O NOT CLEAN FOAM RUBBER FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE . KTM PUTOLINE THE FOAM RECOMMENDS THE PRODUCTS OF THE COMPANY . -
Page 32: Adjusting The Clutch Cable
Adjusting the clutch cable When the engine is cold, the play at the clutch lever should be 1-3 mm (0.04-0.12 in) (measured at the outer edge). To adjust the clutch cable turn the adjusting nut accordingly. 1-3 mm Checking the adjustment of the hand decompression cable* To check, set piston at compression, so that the valves are closed. -
Page 33: Engine Oil
Engine oil API: SF, SG, SH Only use high-quality oils meeting or surpassing the quality requirements of API classes SF, SG, or SH (for specifications see containers). You may use TEMPERATURE either mineral oils or synthetic oils fulfilling the above criteria. –... -
Page 34: Changing Oil Filter
To allow the air to escape from the front pipe of the frame, remove plug next to the steering head. Start engine and let it run in idle (1-2 minutes) until oil escapes at the bore . As soon as oil starts to escape, turn off the engine, and mount plug together with the gasket. -
Page 35: Trouble Shooting
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. - Page 36 The ignition (power consumer) Recharge the battery according to the relevant instructions. hasn’t been switched off The battery isn’t charged by the Remove seat and check voltage regulator connections; vol- generator because tage regulator and generator should be checked by a KTM dealer.
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Page 37: Cleaning
CLEANING 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. -
Page 38: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS KTM 640 DUKE e Type 640 DUKE last edition Frame Central chrome-moly-steel frame Fork type WP - 4054 Roma Top adjuster wheel travel 140 mm (5,5 in) standard adjustment compression driver only = 14, with passenger = 14... -
Page 39: Technical Specifications - Engine
TECHNICAL DATA – ENGINE KTM 640 LC4 e Type 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95... - Page 40 TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear M20x1.5 Loctite 242 + 170 Nm (125 ft.lb) Collar nut flywheel M16x1.25 LH thread 80° C + 150 Nm (132 ft.lb) Hexagon nut for inner clutch hub M18x1.5 80 Nm (60 ft.lb) Kickstarter stop screw M12x1.5 50 Nm...
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Page 41: Notices
– Notices –... -
Page 42: Wiring Diagramm
Schaltplan... - Page 43 Beschreibung Schaltplan...
- Page 44 K T M - S P O R T M O T O R C Y C L E A - 5 2 3 0 M a t t i g h o f e n • P o s t f a c h 9 1 • A u s t r i a I n t e r n e t : h t t p : / / w w w .