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Summary of Contents for KTM 640 DUKE II
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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 TECHNICAL SPECIFICATIONS... - Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
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Page 5: Table Of Contents
SERIAL NUMBER LOCATING ..... . .4 General information about KTM disc brakes ..23 Chassis number . -
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). Speedometer The mileage indicator in the speedometer indicates overall mileage. -
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: Starter Tip Switch, Emergency Off Switch
Starter tip switch, emergency OFF tip switch Use the starter tip switch to operate the electric starter. The emergency off switch is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on). -
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: WP 0118W719 ..position 3 Rebound damping of shock absorber With the setting wheel the degree of damping of the rebound can be... -
Page 12: General Tips And Warnings For Starting The Motorcycle10
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 13: 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 14: 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 15: Kickstart Instructions
CAUTION SCALDING HAZARD! - AND CHECK THE COOLING 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 Starting off SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED –... -
Page 16: 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 18: Lubrication And Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE 640 Duke II 2nd Service after 1st Service 5000 km, then 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 ●... - Page 19 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 ●...
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Page 20: 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 21: 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 22: 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 23: 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 24: 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 25: General Information About Ktm Disc Brakes
DOT 4 brake fluid. However, you should replace it as soon as possible by 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! -
Page 26: Changing The Basic Position Of The Handbrake Lever
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. 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 27: 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 28: 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 29: 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 30: Battery
Battery The battery is mounted under the seat (remove the seat, see page 18) 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 31: 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 32: 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 33: 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 34: Checking The Coolant 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 „TWIN AIR“ FOAM RECOMMENDS THE PRODUCTS OF THE COMPANY AIR FILTER MAINTENANCE – H... -
Page 35: 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. CAUTION F THERE IS NO PLAY ON THE CLUTCH LEVER THE CLUTCH WILL START TO SLIP CLUTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS... -
Page 36: 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 37: 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 38: 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 39: 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 40 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 41 Recharge the battery according to the relevant instructions. 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 42: 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 43: Technical Specifications - Engine
TECHNICAL DATA – ENGINE 640 DUKE II 2002 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 11.0 : 1 Fuel unleaded premium gasoline with a least RON 95... -
Page 44: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2002 Frame Central chrome-moly-steel frame Fork type ........WP 4357 ROMA 0518716 wheel travel . - Page 45 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 Loctite 243 + 10Nm (7ft.lb) Bolts brake caliper front...
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Page 46: Head Word Index
Adjusting idle speed ......34 General information about KTM disc brakes ..23 Adjusting the choke cable . - Page 52 321023...
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