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KTM 640 DUKE II 2001 Owner's Handbook Manual

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Summary of Contents for KTM 640 DUKE II 2001

  • Page 3: Important Notes

    (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...
  • Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down. 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.

  • Page 5: Table Of Contents

    Maintaining chain tension eccentrics ....19 General information about KTM disc brakes ...19 HEAD WORD INDEX ......39 WIRING DIAGRAMM .

  • Page 6: Serial Number Locating

    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). WARNING “ ” F THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY NOT ENOUGH RESISTANCE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH...

  • Page 8: Ignition Lock, With 4 Switch Position

    Ignition lock with 4 switch positions Switch positions of ignition lock Ignition off, light off (engine can't be started) Ignition on, light off (engine can be started) Ignition on, light on (engine can be started) Ignition off, light off, handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the...

  • Page 9: Emergency Off Switch

    Emergency OFF switch The red emergency-OFF switch is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrup- ted. The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter.

  • Page 10: Shift Lever

    Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located bet- 2,3,4,5 ween first and second gear. Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.

  • Page 11: Compression Damping Of Shock Absorber

    Compression damping of shock absorber With the knob the degree of damping of the compression can be adju- sted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during rcompressing. STANDARD ADJUSTMENT: position 3 Rebound damping of shock absorber With the setting wheel the degree of damping of the rebound can be...

  • Page 12: Driving Instructions

    Arrange for the braking system to be checked by a KTM speed, tilting the vehicle at different angles so that the sur- specialist garage, as complete failure of the braking system face is evenly roughened.
  • Page 13 – 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

    LIQUID LEVEL Starting off – D O NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COO KTM’ Pull the clutch lever. Put the engine into first gear, slowly LING SYSTEM OWEVER CALL ON ONE OF S DEALERS AS release the clutch lever and open throttle at the same time.

  • 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 – N EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING –...

  • Page 16: Lubrication And Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE 2001 640 Duke II 2. Service after 5000 km, then 1. 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 filter, 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 17 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for competi- once a year start cleaning tion use Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper function Check horn for proper function Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals...

  • Page 18: 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 19: 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 20: 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 21: Chain Maintenance

    If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn. In this case, consult an authorized KTM dealer immediately.

  • Page 22: Changing The Basic Position Of The Handbrake Lever

    DOT 5.1. Never use brake fluid DOT 5. The color of this silicon oil-based product is purple red. The gaskets and brake hoses of KTM motorcycles are not desi- gned for DOT 5 brake fluid! Changing the basic position of the handbrake lever The adjusting screw 1 allows you to change the basic position of the hand- brake lever 2.

  • Page 23: Checking The Front Brake Pads

    Checking the front brake pads min. The brake pads can be inspected from behind. Always inspect the brake pad 1 mm linings before taking off on your motorcycle. They should not be thinner than 1 mm which is the case when the notch is no longer discernable.

  • Page 24: Checking The Rear Brake Pads

    Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). 1 mm WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE OR YOUR OWN SAFETY ’...

  • Page 25: 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 26: Battery

    Battery The battery is mounted under the seat (remove the seat, see page 9) MAINTENANCE: 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 27: 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.

  • Page 28: 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 29: Stop Light And Tail Light - Replacing Bulb

    COOLING SYSTEM FOR LEAKS LSO CHECK IF THERE IS ENOUGH COOLING LIQUID CAUTION - SCALDING HAZARD! D O NOT DRIVE ON UNTIL THERE IS SUFFICIENT KTM’ LIQUID IN THE COOLING SYSTEM OWEVER CALL ON ONE OF S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED...

  • Page 30: Checking The Coolant Level

    Checking the coolant level The coolant should be 10 mm (0,4 in) above the radiator fins when the engine is cold (see illustr.). In the event of the coolant being drained, always fill and bleed the system. 10 mm, 0,4 in WARNING –...

  • Page 31: Adjusting Idle Speed

    Adjust idling speed * Use the adjusting screw to adjust the basic position of the throttle valve and, thus, the idle speed.Turning in clockwise direction will increase the idling speed, turning in counterclockwise direction will reduce the idling speed. Normal idling speed 1400 - 1500 rpm. Draining of float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carbure- tor should be drained in order to remove any water that may have penetra-...

  • Page 32: Engine Oil

    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 33: 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 34: 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 35 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 36 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.

  • 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 - Engine

    TECHNICAL DATA – ENGINE 640 DUKE II 2001 Type 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 624,6 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95...

  • Page 39: Technical Specifications - Chassis

    TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2001 Frame Central chrome-moly-steel frame Fork type ........WP - USD Roma wheel travel .
  • Page 40 TIGHTENING TORQUES - CHASSIS DUKE II Collar nut front axle 40 Nm (30ft.lb) Collar nut rear axle M20x1,5 80 Nm (59ft.lb) Shock absorber top 45 Nm (33ft.lb) Shock absorber bottom 45 Nm (33ft.lb) Collar screws brake disk front Loctite 243 + 10Nm (7ft.lb) Collar screws brake disk rear Loctite 243 + 10Nm...

  • Page 41: Head Word Index

    Battery ........24 General information about KTM disc brakes ..19 Cassis number .

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