Oil Circuit; Oil, Oil Filter And Screen Filter Change, Bleeding Of The Oil System - KTM 640 DUKE II 2005 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
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Oil circuit

The oil pump [1] pumps the motor oil past the bypass valve [2] and through
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the oil filter [3] . Beyond the oil filter, one of the oil lines forks off to the jets
[4] that injects motor oil to the piston pin bearing and the piston head. The
second oil line leads the main oil flow to the frame breast pipe [5] where the
motor oil is cooled off. Then the motor oil flows through the fine screen filter
[6] that removes even the finest of contaminants from the motor oil. The cleansed
motor oil is pumped via an oil line and the clutch cover into the crankshaft
to the conrod bearing [7] and drains from there into the crank case. A addi-
tional oil pump [8] suctions the motor oil out of the crank case and pumps it
through the oil canal [9] to the gear wheels of the 4th and 5th gears. The
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motor oil reaches the oil sump via the gear wheels. The timing chain [10] also
dips into the oil sump and propels motor oil upwards to the cylinder head.
The motor oil reaches the camshaft [12] and the valves through the bore [11].
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Oil, oil filter and screen filter change, bleeding of the oil system *

A
Note: The frame breast pipe is integrated into the oil circuit for the sake of
more effectively cooling the motor oil. It is thus important when changing the
oil to also remove the fine screen filter, to drain the motor oil from the breast
pipe and to de-aerate the oil system.
If the oil system is not bled at all or bled insufficiently, the bearings of the engine
will not get enough lubrication, which in turn may result in engine failure.
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.
The engine oil change is to be carried out when the engine is still warm.
AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT IS VERY HOT
– DO NOT BURN YOURSELF.
Place the motorcycle on a horizontal surface. Remove the two plugs [13] and
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[14], and drain oil into a container.
PLUG [A] MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.
Remove the screws and the cover [15]. Loosen the fine screen filter [6] with
an oil filter wrench and then screw it off by hand.
The screw [16] must be removed to allow the motor oil to flow out of the frame
breast pipe (see page 36).
Replace the oil filter when changing the engine oil. Press the foot brake pedal
and place a screwdriver or similar between foot brake pedal and
stopper roll so that the oil filter cover is more accessible. Remove banjo bolt
[19] and the three screws. Remove oil filter cover [20] and oil filter. Clean
the filter case, oil filter cover and sealing areas. Make sure the oil duct in the
oil filter cover is not clogged.
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