Changing The Spring Preload Of The Shock Absorber; Checking The Rubber Ring Of The Rear Shock Absorber; Lubricating The Shock Absorber Linkage - KTM 640 DUKE II 2003 Owner's Manual

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min. 2,5 mm
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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
considerably more or less than 75 kg (165 lb), you should change the spring
preload accordingly. This is easily done.
NOTE:
– Before changing the spring preload note down the basic setting, e.g.
how many threads are visible above the adjusting ring.
– One rotation of the adjusting ring
approximately 2 mm.
Loosen the allan head screw
3
wrench from the tool set to turn the adjusting ring as required. Place the
adjusting ring in a suitable position, and tighten the allan head screw with
8 Nm (6 ft.lb).
ADJUSTMENT VALUES - SPRING PRELOAD:
Minimum preload...............................................................10 mm
Preload driver only 75 kg BASIC SETTING ..........................23 mm
Preload with passenger.......................................................28 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 loses its shock absor-
bing quality.
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.
!
N
OT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE SHOCK
.
ABSORBER
WARNING
T
HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED
. N
NITROGEN EVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN
. S
ANCE WORK YOURSELF EVERE INJURIES COULD BE THE RESULT

Lubricating the shock absorber linkage

The bearings in the rocker arm must be greased in regular intervals. For this
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purpose, a grease nipple is mounted on the rocker arm.
!
A
FTER EACH TIME THE MOTORCYCLE IS WASHED
GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS
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changes the spring preload by
1 2
at the adjustment ring
CAUTION
.
CAUTION
,
IT IS ESPECIALLY IMPORTANT TO
. Use the special
!
-
!
.