Related Manuals for KTM 640 DUKE II 2004
Summary of Contents for KTM 640 DUKE II 2004
- Page 1 BEDIENUNGSANLEITUNG2004 640 DUKE II OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.210.87...
- Page 2 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS...
- Page 3 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 should be performed by a qualified KTM dealer.
- Page 4 In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
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Page 5: Table Of Contents
OPERATION INSTRUMENTS ......5 General information about KTM disc brakes ..23 Clutch lever . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis 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: Hand Brake Lever
Hand brake lever The hand brake lever is mounted on the right side of the handlebar.The basic position of the handbrake lever can be changed in 4 steps (see Maintenance work on chassis and engine). Speedometer The mileage indicator in the speedometer indicates overall mileage. -
Page 8: Combination Switch
Combination switch The rocker switch LIGHTS actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button The light signal (high beam) is actuated with button Starter tip switch, emergency OFF tip switch, light switch Use the starter tip switch... -
Page 9: 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 10: Compression Damping Of Fork
Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. The damping rate of the compression damping mechanism can be readju- sted at the adjusting screws located at the fork leg. -
Page 11: General Tips And Warnings For Starting The Motorcycle
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE LEVER OF VEHICLE jobs (see Customer Service Manual). DRIVERS ALWAYS WEAR A HELMET... -
Page 12: Driving Instructions
Arrange for the braking system to be checked by a KTM specialist garage, as complete failure of the braking system can be expected. Also check the state of the brake hoses and the thickness of the brake linings. -
Page 13: Starting When The Engine Is Cold
– 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 STAR-... -
Page 14: 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 15: Stopping And Parking
Stopping and parking Apply the brakes fully and put the engine into neutral. To stop the engine, switch off the ignition. Close fuel tap. Park on solid ground and lock the vehicle. WARNING – M OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING ENGINE RADIATORS EXHAUST EXHAUST SYSTEM... -
Page 16: Activating The Ignition Curve For Low-Octane Fuel
Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (ROZ) is not available, you can easily activate the corresponding ignition curve. A plug and socket connection on a brown/black cable is located on the right side of the vehicle next to the CDI box . -
Page 17: Periodic Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE 640 Duke II 2nd Service after 5000 km, then 1st Service A washed motorcycle can be checked more quickly which saves money! after every 5000 km or 1000 km once a year Change engine oil, oil filters, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km... - Page 18 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every once a year start cleaning Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals...
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Page 19: Maintenance Work On Chassis And Engine
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 DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. -
Page 20: Checking And Adjusting The Steering Head Bearing
Checking and adjusting the steering head bearing* Check steering head bearing for play periodicaly. To check this, put motorcycle on stand so that the front wheel is off the ground. Now try to move the fork forward and backward - no play should be discernable To adjust, loosen the five clamp screws of the top triple clamp and turn steering stem bolt clockwise... -
Page 21: Changing The Spring Preload Of 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 rubber ring replaced in a KTM garage when compaction due to wear has exceeded the limit. -
Page 22: Checking Chain Tension
Checking chain tension To check chain tension, turn off the engine and shift into neutral. Chain tension is correct when the chain can just barely be pushed up to touch the swingarm at the level of the screw (see illustration). If necessary, correct chain tension. -
Page 23: Chain Wear
Chain wear In order to check the chain wear, regard the following instructions: Shift the gear into idling and pull the upper chain strand with approx. 10-15 kilogramm (33 lb) upwards (see figure). Now one can measure a space of 15 KG 18 chain reels at the lower chain strand. -
Page 24: General Information About Ktm Disc Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 25: Changing The Basic Position Of The Handbrake Lever
Changing the basic position of the handbrake lever The adjusting screw allows you to change the basic position of the hand- brake lever Press the handbrake lever's outer end forward, and, at the same time, turn the adjusting screw. Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. -
Page 26: Changing The Basic Position Of The Foot Brake Pedal
Changing the basic position of the foot brake pedal* The basic position of the foot brake pedal can be altered by turning the stop roller . The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside, the foot brake pedal must have 3-5 mm (0,12–0,20 in) of free play, before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot... -
Page 27: Dismounting And Mounting The Front Wheel
Dismounting and mounting the front wheel* To remove the front wheel, jack the motorcycle up by the frame so that the front wheel no longer touches the ground. Take out both AH screws and remove brake caliper from brake disc. CAUTION HEN REMOVING THE BRAKE CALIPER MAKE SURE THAT THE BRAKE LINE... -
Page 28: Checking The Damping Rubbers In The Rear Wheel
Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires. WARNING – D KTM. O O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY THER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES –... -
Page 29: Battery
Charging the battery NOTE: A battery charger, item no. 58429074000 is available from your KTM dealer. You can also use the battery charger to test the battery's off load voltage, startability and the generator capacity. Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). -
Page 30: Main Fuse
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 inspected by a KTM dealer. The fuse capacity is 20 Ampere. CAUTION –... -
Page 31: Headlight Range Adjustment
Headlight range adjustment * The range by the low beam and the high beam can be adjusted by means of the screws These screws are accessible when the headlight mask is opened. Turn the screws clockwise to reduce the distance lighted. Turn the screws counterclockwise to increase the distance lighted. -
Page 32: Stop Light And Tail Light - Replacing The Bulb
CAUTION SCALDING HAZARD! Do not drive on, until there is sufficient liquid in the cooling system. Go to your nearest KTM garage and get it seen to. If you drive with the cooling liquid temperature warning light on, you will cause even more damages to the engine. -
Page 33: Checking The Cooling Liquid Level
, and lock into place with the filter holder CAUTION – D O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE . KTM „MOTOREX“ FOAM RECOMMENDS THE PRODUCTS OF THE COMPANY AIR FILTER MAINTENANCE – H... -
Page 34: Changing The Original Position Of The Clutch Lever
4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex Clutchfluid 75).Biodegradable hydraulic oil is available from your KTM dealer (50ml). CAUTION USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL... -
Page 35: Adjust Idling Speed
Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). 5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. -
Page 36: Oil Circuit
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. -
Page 37: Changing Oil Filter
BLEEDING THE OIL SYSTEM To facilitate bleeding of the oil system, we have added a hose connection 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 from the inside with the M8 hexagon nut. -
Page 38: 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 39 Check vacuum hose and venting hoses of carburetor for cor- rect position (no kinks) Air filter very dirty Clean or replace air filter, contact a KTM dealer Valve clearance to small Have valve clearance adjusted Loss of compression because hand...
- Page 40 Recharge the battery according to the relevant instructions. The battery is discharged hasn’t been switched off The battery isn’t charged by the Remove seat and tank and check voltage regulator connec- generator because tions; voltage regulator and generator should be checked by a KTM dealer.
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Page 41: 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 42: Technical Data - Engine 640 Duke Ii 2004
TECHNICAL DATA – ENGINE 640 DUKE II 2004 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 11.7 : 1 Fuel unleaded premium gasoline with a least RON 95... -
Page 43: Technical Specifications - Chassis 640 Duke Ii 2004
TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2004 Frame Central chrome-moly-steel frame Fork type........WP 43 ROMA 1418Y755 wheel travel. - Page 44 TIGHTENING TORQUES - CHASSIS Collar nut front axle 40 Nm (30ft.lb) Collar nut rear axle M20x1.5 80 Nm (59ft.lb) Shock absorber bolts top 45 Nm (33ft.lb) Shock absorber bolts bottom 45 Nm (33ft.lb) Collar screws brake disk front + rear M6 (10.9) Loctite 243 + 10Nm (7ft.lb)
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Page 45: Head Word Index
Activating the ignition curve for low-octane fuel ..15 General information about KTM disc brakes ...23 Adjust idling speed ......34 General tips and warnings for starting the motorcycle . - Page 47 tachometer headlight temperature control lamp flasher control lamp speedometer driving light lamp idle control lamp ye-bu front brake switch gn-bl gn-bl ye-bl head light flascher gn-re ye-br gn-br bu-bl bu-re bu-bl or-bl br-pi gn-bl bl-bu ignition coil bl-wh bl-or bu-wh ye-br ye-wh re-ye...
- Page 48 ENGLISH DEUTSCH ITALIANO Battery Batterie Batteria Capacitor Kondensator Condensatore Clutch switch Kupplungsschalter Interruttore frizione Cooling fan Lüftermotor Motorino ventola Diode Diode Diodo Driving light control lamp Fernlichtkontrolle Driving light control lamp flasher control lamp Blinkerkontrolllampe Spia lampeggiatori Flasher relay Blinkerrelais Relè...
- Page 49 ENGLISH FRANCAIS ESPANOL Battery Batterie Batería capacitor condensateur condensador Clutch switch Contacteur d’embrayage Interruptor de embrague Cooling fan Ventilateur Motor del ventilador Diode Diode Diodos driving light control lamp temoin de feu route lampara aviso luces largas flasher control lamp temion de clignoteur lampara aviso intermitentes Flasher relay...
- Page 50 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...