Periodic Maintenance Schedule - KTM 640 DUKE II 2003 Owner's Manual

A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filters, 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
Check and adjust valve clearance
Check engine fastening screws for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper function
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
16
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/foot brake levers
Check screws of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Service eccentric for chain tension
Lubricate reversing lever
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws,
swinging-fork pivot, reversing lever, suspension strut)
Check tire condition, inflation pressure, and rim condition
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of the silencers
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S
ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN
M
AINTENANCE WORK DONE BY

PERIODIC MAINTENANCE SCHEDULE

KTM
AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER
640 Duke II
2nd Service after
1st Service 5000 km, then
after every 5000 km or
1000 km once a year
at least every 2 years
once a year or 20000 km
500 !
KM
!