Checking Chain Tension; Correcting Chain Tension; Chain Maintenance - KTM 640 DUKE II 2003 Owner's Manual

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2
3

Checking chain tension

To check chain tension, turn off the engine and shift into neutral. Chain
1
tension is correct when the chain can just barely be pushed up to touch the
swingarm at the level of the screw
chain tension.
– I
F CHAIN TENSION IS TOO GREAT
(
,
SION
CHAIN
SUBJECTED TO UNNECESSARY STRESS
CHAIN BREAKAGE
– T
OO MUCH SLACK IN THE CHAIN
JUMPING OFF THE CHAIN WHEELS
THE REAR WHEEL OR DAMAGE THE ENGINE
– I
N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE

Correcting chain tension

Loosen hexagon nuts
Loosen allan head screw
Insert the hexagon socket wrench that comes with the tool set into the
hexagon socket of the eccentric and rotate the eccentric upwards
(i.e. the wheel spindle must move upwards).
!
I
F THE WHEEL SPINDLE BECOMES LOOSENED DURING THE PROCESS
TO
THEIR
ORIGINAL
(
M
SEE
AINTAINING
Tighten hexagon nuts on swing arm fists to 40 Nm (30 ft.lb).
Tighten allan head screw
– D
O NOT ROTATE THE ECCENTRIC DOWNWARDS
). T
DOWNWARDS
'
MOTORCYCLE
– I
'
F YOU DON
T HAPPEN TO HAVE A TORQUE WRENCH AT HAND
HAVE THE TIGHTENING TORQUE CORRECTED BY A
.
POSSIBLE

Chain maintenance

For long chain life, good maintenance is very important. X-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 X-ring chain spray (Motorex Chainlube Racing).
N
O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK
THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY
REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL
!
W
HEN MOUNTING THE CHAIN JOINT
POINT IN RUNNING DIRECTION
Also check sprockets and chain guides for wear, and replace if necessary.
1
(see illustration). If necessary, correct
WARNING
,
PARTS WITHIN THE SECONDARY POWER TRANSMIS
,
CHAIN SPROCKETS
TRANSMISSION AND REAR WHEEL BEARINGS
,
RESULTING IN PREMATURE WEAR AND EVEN
.
,
ON THE OTHER HAND
. I
F THIS HAPPENS
.
2
on the left and right swingarm fists.
3
.
CAUTION
POSITION
BEFORE
RETIGHTENING
E
)
CCENTRICS
3
to 40 Nm (30 ft.lb).
WARNING
HIS WILL RAISE THE TAIL OF THE MOTORCYCLE AND WORSEN THE
S PERFORMANCE ON THE STRAIGHTAWAY
WARNING
CAUTION
,
THE CLOSED SIDE OF THE SAFETY DEVICE MUST
.
-
)
WILL BE
,
CAN RESULT IN THE CHAIN
,
THE CHAIN COULD ALSO BLOCK
.
!
,
RETURN ECCENTRICS
THE
WHEEL
SPINDEL
(
.
.
I
E
THE WHEEL SPINDLE MOVES
.
,
MAKE SURE YOU
KTM
DEALER AS SOON AS
,
EITHERWISE
.
!
21

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