KTM 640 DUKE II 2005 Owner's Manual
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KTM 640 DUKE II 2005 Owner's Manual

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BEDIENUNGSANLEITUNG2005
640 DUKE II
OWNER'S MANUAL
MANUALE D'USO
MANUEL D'UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.50

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Summary of Contents for KTM 640 DUKE II 2005

  • Page 1 BEDIENUNGSANLEITUNG2005 640 DUKE II OWNER’S MANUAL MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.50...
  • Page 2 KTM may stop manufacturing cer- tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con- tain extra equipment, which is not applied to standard models.
  • Page 3 Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.

  • Page 4: Important Limited Warranty And Limited Guarantee Information

    In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

  • Page 5: Table Of Contents

    OPERATION INSTRUMENTS .....5 General information about KTM disc brakes ..23 Changing the basic position of the handbrake lever . .24 Clutch lever .

  • Page 6: Serial Number Locations

    » 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

    » OPERATION INSTRUMENTS Hand brake lever The hand brake lever [1] 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 [A] in the speedometer [2] indicates overall mileage.

  • Page 8: Combination Switch

    » OPERATION INSTRUMENTS Combination switch The rocker switch LIGHTS [1] actuates the high beam or low beam. High-beam light Low-beam light The indicator switch [2] returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher The horn is sounded with button [3].

  • Page 9: Fuel Tap

    » OPERATION INSTRUMENTS Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. When using the motorcycle, the twist grip must be set to the ON posi- tion. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx.

  • Page 10: Compression Damping Of Fork

    » OPERATION INSTRUMENTS Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. The damping rate of the compression damping mechanism can be readjusted at the adjusting screws [1] located at the fork leg.

  • Page 11: General Tips And Warnings For Starting The Motorcycle

    Even finely machined surfaces of engine parts have rougher sur- faces than parts that slide on each other for a long time. Therefore, – ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR every engine must be run in. For this reason, do not demand max- EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPER- imum performance from the engine for the first 1000 kilometers.

  • Page 12: Driving Instructions

    If the level of brake fluid falls below the min- imum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist garage, as complete failure of the braking system can be expected.

  • Page 13: 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...

  • Page 14: Kickstart Instructions

    ESCAPE. – CAUTION SCALDING HAZARD! – AND CHECK THE COOLING LIQUID LEVEL. – DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEAL- ERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.

  • Page 15: Stopping And Parking

    » DRIVING INSTRUCTIONS 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. – MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN- NING.

  • Page 16: Activating The Ignition Curve For Low-Octane Fuel

    » DRIVING INSTRUCTIONS Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (RON) is not available, you can easily activate the corresponding ignition curve. A plug and socket connection [1] on a brown/black cable is located on the right side of the vehicle next to the CDI box .

  • Page 17: Periodic Maintenance Schedule

    IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
  • Page 18 » PERIODIC MAINTENANCE SCHEDULE IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER at least every 2 years once a year or 20000 km 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...

  • Page 19: 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 SERV- ICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.

  • Page 20: Checking And Adjusting The Steering Head Bearing

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking and adjusting the steering head bearing* Check steering head bearing for play periodicaly. To check this, put motorcy- cle 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 [1] of the top triple clamp and turn steering stem bolt clockwise [2] until there is no more play.

  • Page 21: 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 22: Checking Chain Tension

    DOWNWARDS). THIS WILL RAISE THE TAIL OF THE MOTORCYCLE AND WORSEN THE MOTORCYCLE’S PERFORMANCE ON THE STRAIGHTAWAY. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. Chain maintenance For long chain life, good maintenance is very important.

  • Page 23: Chain Wear

    Adjust the chain tension. IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. IF THE ECCENTRICS ARE NOT ALIGNED, THE REAR WHEEL WILL REST AT AN ANGLE IN THE SWING ARM.

  • Page 24: General Information About Ktm Disc Brakes

    CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI- ATELY AS SOON AS THEY REACH THE WEAR LIMIT. – HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake fluids that is currently available.

  • Page 25: Changing The Basic Position Of The Handbrake Lever

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * When the brake fluid falls to the middle of the inspection glass, new brake fluid has to be added.

  • Page 26: Changing The Basic Position Of The Foot Brake Pedal

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir* When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir.

  • Page 27: Dismounting And Mounting The Front Wheel

    243 TO PREVENT LOOSENING. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. – IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE, OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

  • Page 28: 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. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES.

  • Page 29: Battery

    Storage temperature: 0 - 35° C. Do not expose to direct sun radiation. Charging the battery NOTE: A battery charger, item no. 58429074000 is available from your KTM dealer. You can also use the battery charger to test the battery's off load voltage, starta- bility and the generator capacity.

  • Page 30: Main Fuse

    KTM dealer. The fuse capacity is 20 Ampere. – UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE „REPAIRED“.

  • Page 31: Headlight Range Adjustment

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Headlight range adjustment * The range by the low beam [1] and the high beam [2] can be adjusted by means of the screws [3]. These screws [3] are accessible when the headlight mask is opened. Turn the screws clockwise to reduce the distance lighted.

  • Page 32: Stop Light And Tail Light - Replacing The Bulb

    EXAMINE THE COOLING LIQUID LEVEL – CAUTION SCALDING HAZARD! DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYS- TEM. GO TO YOUR NEAREST KTM GARAGE AND GET IT SEEN TO. IF YOU DRIVE WITH THE COOLING LIQUID TEMPERATURE WARNING LIGHT ON, YOU WILL CAUSE EVEN MORE DAMAGES TO THE ENGINE.

  • Page 33: Checking The Cooling Liquid Level

    [1]. – DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY „MOTOREX“ FOR AIR FILTER MAINTENANCE. – HAVING MOUNTED THE AIR FILTER, CHECK IT FOR CORRECT FIT. THE FRONT END A MUST ABOUT THE AIR FILTER BOX.

  • Page 34: Changing The Original Position Of The Clutch Lever

    If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), available from your authorized KTM workshop. KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.

  • Page 35: Adjust Idling Speed

    32°F Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- 5W/40 10W/50 peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 36: 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 37 Remove screw connection on the clutch cover, fill with 1.3 litre engine oil and attach plug again. – USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. USING ANOTHER FILTER BRAND CAN RESULT IN DAMAGE TO THE ENGINE. – IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE...

  • Page 38: 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 39 Carburetor leaking 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...
  • Page 40 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.

  • Page 41: 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 42: Technical Specifications - Engine

    Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 43: Technical Specifications - Chassis

    » TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 640 DUKE II Frame Central chrome-moly-steel frame Fork type ......WP 4357 MXMA 05187A03 wheel travel .
  • Page 44 » TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS 640 DUKE II Front axle 40 Nm Rear axle M20x1,5 80 Nm Shock absorber bolts top 45 Nm Shock absorber bolts bottom 45 Nm Collar screws brake disk front / rear M8 / M6 10.9 Loctite 243 + 14 Nm Bolts brake caliper front...

  • Page 45: Head Word Index

    Page Activating the ignition curve for low-octane fuel ..15 General information about KTM disc brakes ..23 Adjust idling speed ......34 General tips and warnings for starting the motorcycle .

  • Page 47: Wiring Diagramm

    » SCHALTPLAN WIRING DIAGRAM tachometer headlight temperature control lamp flasher control lamp speedometer driving light lamp idle control lamp ye-bu front brake switch gn-bl gn-bl ye-bl head light flascher gn-re ye-br gn-br bu-bl bu-re bu-bl or-bl br-pi gn-bl bl-bu ignition coil bl-wh bl-or bu-wh...
  • Page 48 » SCHALTPLAN WIRING DIAGRAM ENGLISH DEUTSCH ITALIANO Battery Batterie Batteria Capacitor Kondensator Condensatore Clutch switch Kupplungsschalter Interruttore frizione Cooling fan Lüftermotor Motorino ventola Diode Diode Diodo Driving light control lamp Fernlichtkontrolle Driving light control lamp flasher control lamp Blinkerkontrolllampe Spia lampeggiatori Flasher relay Blinkerrelais Relè...
  • Page 49 » SCHALTPLAN WIRING DIAGRAM ENGLISH FRANCAIS ESPANOL Battery Batterie Batería capacitor condensateur condensador Clutch switch Contacteur d’embrayage Interruptor de embrague Cooling fan Ventilateur Motor del ventilador Diode Diode Diodos driving light control lamp temoin de feu route lampara aviso luces largas flasher control lamp temion de clignoteur lampara aviso intermitentes...
  • Page 50 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

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