Table Of Contents - KTM 640 DUKE II Owner's Handbook Manual

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SERIAL NUMBER LOCATING . . . . . . . . . . . . . . . . . . . . . . .4
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .4
Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ignition lock, with 4 switch position . . . . . . . . . . . . . . . .6
Ignition lock with 3 switch position . . . . . . . . . . . . . . . . .6
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Starter tip switch, emergency OFF switch . . . . . . . . . . . .7
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of shock absorber . . . . . . . . . . . .9
Rebound damping of shock absorber . . . . . . . . . . . . . . .9
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE10
Instructions for initial operation ......................................10
Running in......................................................................10
DRIVING INSTRUCTIONS...................................................11
Check the following before each start ............................11
Starting when the engine is cold.....................................12
Starting when the engine is warm ..................................12
What to do when the engine is flooded..........................12
Kickstart instructions.......................................................13
Starting off .....................................................................13
Shifting, Riding...............................................................13
Braking...........................................................................13
Stopping and parking .....................................................14
Fuel ................................................................................14
LUBRICATION AND MAINTENANCE SCHEDULE . . . . . . .16
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .18
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Supporting strap for the passenger . . . . . . . . . . . . . . . .18
Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Checking and adjusting the steering head bearing . . . .19
Bleeder screw front fork . . . . . . . . . . . . . . . . . . . . . . . .19
Cleaning the dust sleeves of the telescopic fork . . . . . . .19
Changing the spring preload of the shock absorber . . . .20
Checking the rubber ring on the shock absorber . . . . . .20
Lubricate rear shock absorber linkage . . . . . . . . . . . . . .20
Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . . .21
Correcting chain tension . . . . . . . . . . . . . . . . . . . . . . . .21
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
INDEX
Page
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Maintaining chain tension eccentrics . . . . . . . . . . . . . . .22
General information about KTM disc brakes . . . . . . . . .23
Changing the basic position of the handbrake lever . . .24
Checking of brake fluid level - front brake . . . . . . . . . .24
Refilling the front brake fluid reservoir . . . . . . . . . . . . .24
Checking the front brake pads . . . . . . . . . . . . . . . . . . .24
Changing the basic position of the brake pedal . . . . . . .25
Checking the rear brake fluid level . . . . . . . . . . . . . . . .25
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .25
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .25
Dismounting and mounting the front wheel . . . . . . . . .26
Dismounting and mounting the rear wheel . . . . . . . . . .26
Checking the damping rubbers in the rear wheel . . . . .27
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fuses for indivitual power-consuming units . . . . . . . . . .29
Opening the head light mask . . . . . . . . . . . . . . . . . . . .29
Headlight range adjustment . . . . . . . . . . . . . . . . . . . . .30
Headlight - replacing the bulbs . . . . . . . . . . . . . . . . . . .30
Parking light - replacing the bulb . . . . . . . . . . . . . . . . .30
Flasher - replacing the bulbs . . . . . . . . . . . . . . . . . . . . .30
Stop light and tail light - replacing bulb . . . . . . . . . . . . .31
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .32
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Adjusting the clutch cable . . . . . . . . . . . . . . . . . . . . . . .33
Checking the setting of the hand decompression cable .33
Adjusting the choke cable . . . . . . . . . . . . . . . . . . . . . . .33
Adjusting idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Draining of float chamber of the carburetor . . . . . . . . .34
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . .34
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Change of oil and fine screen filter, bleeding of the oil
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .37
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .40
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Re-initation after time of storage . . . . . . . . . . . . . . . . .40
TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . . .41
TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .42
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . . . . .
CONSUMER INFORMATION FOR USA ONLY . . . . .
Page
3
APPENDIX
APPENDIX