640 DUKE II BEDIENUNGSANLEITUNG OWNER'S MANUAL MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art.Nr. 3.210.58 2/2003 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS, MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION. KTM SPORTMOTORCYCLE AG ENGLISH 1 WARNING 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 sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it. We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer. For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. 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. Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others. We wish you a lot of fun when driving ! ENGLISH 2 KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL. © by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The 640 DUKE model is designed for regular on-road service but not for use off of paved roads. The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty. The fuels and lubricants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule. The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle. The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. ENGLISH 3 INDEX Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .5 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .5 Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ignition lock with 3 switch positions . . . . . . . . . . . . . . . .6 Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Starter tip switch, emergency OFF tip switch, light switch 7 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Compression damping of fork . . . . . . . . . . . . . . . . . . . .9 Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .9 Compression damping of shock absorber . . . . . . . . . . . .9 Rebound damping of shock absorber . . . . . . . . . . . . . . .9 Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 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 Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Activating the ignition curve for low-octane fuel . . . . .15 PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .16 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 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 of the rear shock absorber . .20 Lubricating the shock absorber linkage . . . . . . . . . . . . .20 Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . .21 CONSERVATION FOR WINTER OPERATION . . . . . . . . . .40 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Re-initiation after time of storage . . . . . . . . . . . . . . . . .40 TECHNICAL DATA ­ ENGINE 640 DUKE II 2003 . . . . . .41 TECHNICAL SPECIFICATIONS - CHASSIS 640 DUKE II 2003 .42 HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . . . .appendix Page Correcting chain tension . . . . . . . . . . . . . . . . . . . . . . . .21 Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .21 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 foot 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Opening the headlight 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 the bulb . . . . . . . . .31 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Checking the cooling liquid level . . . . . . . . . . . . . . . . .32 Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Changing the original position of the clutch lever . . . . .33 Checking the oil level of the hydraulic clutch . . . . . . . .33 Checking and adjusting the choke cable play . . . . . . . .33 Checking the adjustment of the hand decompression cable * 33 Adjust idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Draining of float chamber of the carburetor . . . . . . . . .34 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Checking the engine oil level . . . . . . . . . . . . . . . . . . . .34 Oil circuit . . . . . . . . ...