User manual KTM 640 LC4 DUKE II - 2003

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Oil and screen filter change, bleeding of the oil system .35 Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 ENGLISH 4 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. The engine number and engine type are stamped on the right hand side of the engine below the engine sprocket. Write the number into the box on page no 1. 1 OPERATION INSTRUMENTS Clutch lever The clutch lever 1 is fitted on the left hand side of the handle bar. The adjusting screw A is used to change the original position of the clutch lever (see maintenance work on chassis and engine). A Hand decompression lever 2 The hand decompression lever 2 is only used in two special cases: a) When the engine stalled. It is possible that the starter motor is not able to crank the engine on the next attempt. This is due to the fact that the automatic decompressor doesn't work properly. If this happens, pull the manual decompression lever and start again. Afterwards normal starting will be possible. b) When you want to push the motorcycle. While pushing, pull the hand decompression lever to make it easier to get the engine going. Choke lever When the choke lever 3 is pulled backwards, a bore is opened in the carburetor which enables the engine to draw in additional fuel. This produces a ,,rich" fuel/air mixture necessary for cold start. When the choke lever is pushed forward as far as it will go, the bore will be closed again. In this position the choke cable must have a play of approx. 2 mm. 3 ENGLISH 5 Engine number, engine type 1 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 ENGLISH 6 C 2 A The mileage indicator A in the speedometer 2 indicates overall mileage. The day mileage indicator B can be set to 0 by means of the setting wheel C. Turn the setting wheel forward until only zeros can be seen in the display. B Tachometer The tachometer 3 shows the engine speed in revolutions per minute (rpm). Do not push the engine into the orange zone, which begins at 8500 rpm. 3 Indicator lamps The green indicator lamp flashes when the flasher light is working in the same rhythm as the flasher light. Faster flashing of the flasher control lamp indicates a defect bulb The blue indicator lamp lights up when the high beam is on. The green indicator lamp lights up when the neutral gear is selected The red cooling liquid temperature warning lamp lights up as soon as the cooling liquid has reached a temperature of approximately 110° C (230° F). Ignition lock with 3 switch positions Switch positions of ignition lock 4: Ignition off, (engine can't be started) Ignition on, (engine can be started) Ignition off, handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar all the way to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and . 4 1 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. 4 The horn is sounded with button 3. The light signal (high beam) is actuated with button 4. 4 2 3 Starter tip switch, emergency OFF tip switch, light switch 6 Use the starter tip switch 5 to operate the electric starter. The light switch has 3 positions: = Light off = Parking light on = Headlight on 5 The emergency off switch 6 is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on). The engine cannot be started in position (ignition circuit and starter circuit are interrupted). Filler cap The filler cap 7 can be locked and is provided with a fuel evaporation control system. To open the cap insert the ignition key, turn it 90° counterclockwise, then lift off the filler cap. To close the tank insert the filler cap, turn the ignition key 90° clockwise and take out the key. 7 ENGLISH 7 Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx. 2.5 liters. RES The reserve, approximately 2.5 liters, cannot be tapped until the twist grip is turned to the RES position. Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time, too. ! THE CAUTION ! FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE. 8 Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4,5 N 1 Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. NO NO NO ENGLISH OFF RES FUEL ON RES FUEL RES RES FUEL O FF O FF O FF Foot brake pedal The foot brake pedal is located in front of the right footrest. The basic position can be adjusted to the seat position (see maintenance work). Compression damping of fork 1 1 Hydraulic compression damping determines the reaction when the fork is compressed. 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. Turn it clockwise to increase damping, and counterclockwise to reduce damping during compression. STANDARD ADJUSTMENT ­ turn adjusting screw clockwise as far as it will go ­ turn it back by as many clicks as are specified for the relevant type of fork WP 0518X732 . . . . . . . . . 14 clicks 2 Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw 2 (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding. STANDARD ADJUSTMENT ­ turn adjusting screw clockwise as far as it will go ­ turn it back by as many clicks as are specified for the relevant type of fork WP 0518X732 . . . . . . . . . 16 clicks Compression damping of shock absorber 3 With the knob 3 the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during rcompressing. STANDARD ADJUSTMENT: WP 0118X728 . . . . . . . . .position 3 Rebound damping of shock absorber With the setting wheel 4 the degree of damping of the rebound can be adjusted to 11 positions. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding. STANDARD ADJUSTMENT: WP 0118X728 . . . . . . . . .position 5 4 Seat lock The seat is secured by the lock on the side of the seat 5 5 ENGLISH 9 2 Rebound damping of fork GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation ­ Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). ­ Read the entire manual carefully before your first drive. ­ Enter the chassis, engine and key numbers on page 1. ­ Familiarize yourself with the operating elements. ­ Adjust the foot brake pedal and the hand brake lever to the most comfortable positions for you. ­ Get used to handling the motorcycle on an empty car park, before starting on a longer drive. Also try to drive as slowly as possible and in standing position, to improve your feeling for the vehicle. ­ Hold the handlebar with both hands and leave your feet on the foot rests while driving. ­ Remove your foot from the foot brake pedal when you are not braking. If the foot brake pedal is not released the brake pads rub continuously and the braking system is overheated. ­ You may only be accompanied by a passenger if your motorcycle is fitted and registered for such purposes. The passenger must hold on to the supporting strap or the driver and keep his feet on the passenger footrests throughout the ride. ­ Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle. ­ New tires have a smooth surface and must be run in. For this purpose, carefully ride the motorcycle at moderate speed, tilting the vehicle at different angles so that the surface is evenly roughened. Tires will not display their full grip characteristics before they are properly run in. ­ Motorcycles are sensitive to alterations in the distribution of weight. If you are taking luggage with you, this should be secured as close as possible to the middle of the vehicle; distribute the weight evenly between the front and rear wheel. Never exceed the maximum permissible laden weight and the axle weights. The maximum permissible laden weight is made up of the following components: ­ Motorcycle ready for operation and tank full ­ Luggage ­ Driver and passenger with protective clothing and helmet. ­ Pay attention to running in instructions. WARNING ­ WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING. ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL. ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE'S DRIVING PROPERTIES. THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE. OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE. ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS. DRIVE CAREFULLY ON UNKNOWN ROADS REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, YOU WILL BE PRACTICALLY BLIND. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING. ­ ­ ­ ENGLISH 10 ­ ­ ­ ­ ­ ­ Running in Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time. Therefore, every engine must be run in. For this reason, do not demand maximum performance from the engine for the first 1000 kilometers. The vehicle must be run in at low, changing performance level for the first 1000 KM (620 miles). The maximum number of revolutions per minute must not go exceed 4800 rpm. Once you have run your engine in for 1000 km (620 mi), you may push it to its 8500 rpm limit , i.e. up to the red zone indicated in the tachometer. Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine. DRIVING INSTRUCTIONS Check the following before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 3 CHAIN A loose chain can fall off; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear to the chain and rear sprockets. 4 TIRES Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure reduce the driving performance. 5 BRAKES Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. If the level of brake fluid falls below the minimum 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. Also check the state of the brake hoses and the thickness of the brake linings. Brake linings measured at their thinnest point should not be less than 1 mm since extremely worn linings can lead to brake failure. WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS "SPONGY" (NOT ENOUGH RESISTANCE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON'T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. 6 CABLES Check correct setting and easy running of all control cables. 7 COOLING LIQUID Check the level of cooling liquid when the engine is cold. 8 ELECTRICAL SYSTEM Check correct functioning of headlamps, parking light, tail-light, brake light, flashers, indicator lamps and horn while the engine is running. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened. 11 ENGLISH 2 FUEL Check that there is sufficient fuel in the tank. Starting when the engine is cold 1 Open the fuel tap. Turn on the ignition. Switch the gear to neutral (green lamp 1 lights). Turn on the emergency OFF switch 2. Operate the choke lever 3. Operate the starter button 5 without accelerating. If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Swing up the sidestand 4. 9 Switch on the light before setting off. WARNING DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING. 1 2 3 4 5 6 7 ENGLISH 12 3 4 6 ! CAUTION ! 2 ­ MAXIMUM ­ PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. DON'T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON'T REV ENGINE WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN MIND THAT THE ENGINE SHOULD BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M. 5 IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: ­ Check if the ignition is on ­ whether the emergency OFF switch ­ Check if the emergency off switch is on ­ the headlight is on. ­ If this is not the case, the battery is discharged ­ If the lights are on, proceed as described in the ,,Trouble-shooting" section or contact a KTM dealer. WARNING WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH. IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE STARTER TIP SWITCH: ­ Check if the fuel tap is open ­ Check if the choke lever has been operated ­ Check if sufficient fuel is in the tank ­ If this is not the case, refill the tank ­ if sufficient fuel is in the tank, proceed as described in the ,,Troubleshooting" section or contact a KTM dealer. THE ELECTRIC STARTER DOESN'T CRANK THE ENGINE WHEN THE STARTER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELECTRIC CURRENT IS AVAILABLE: ­ Pull the hand decompression lever 6, start and release the lever. NOTE: This motorcycle is equipped with a safety starter system. The engine can only be started when the transmission is switched to idle or the clutch lever is pulled, respectively. Motorcycles with side stands are also equipped with a safety starting system. If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop. Starting when the engine is warm 1 2 3 4 5 6 7 Open the fuel tap. Turn on the ignition. Switch the gear to neutral (green lamp 1 lights). Turn on the emergency OFF switch 2. Operate the starter button 5 without accelerating. Swing up the sidestand 4. Switch on the light before setting off. What to do when the engine is ,,flooded" The throttle must be fully opened when starting. If necessary change spark plug. Kickstart instructions Be sure to kick up the side stand before you start the engine to avoid any damage.Start as described above, then push the kickstarter hard all the way. WARNING ­ IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE. ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED THROTTLE GRIP INCREASE THE KICKBACK HAZARD. ! ­ HIGH CAUTION ! ­ ­ ­ ­ ­ ­ ­ Starting off Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time. WARNING YOU START OFF, CHECK THAT THE SIDE STAND HAS BEEN SWUNG RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL. RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN. SHIFT TO THE NEXT HIGHER GEAR BY 8500 RPM AT THE LATEST. ENGINE SPEEDS IN THE RED RANGE MUST STRICTLY BE AVOIDED. NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL. LONG WHEELIE DRIVING CAUSES THE OIL PRESSURE TO DROP. THE OIL PRESSURE WILL AUTOMATICALLY INCREASE AS SOON AS YOU DRIVE ON NORMALLY. DOING WHEELIES FOR A LONG TIME WILL DAMAGE YOUR ENGINE. IF THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE YOU ARE DRIVING, THIS INDICATES COOLING SYSTEM TROUBLE. IMMEDIATELY STOP AND TURN OFF THE ENGINE. DRIVING WITH THE WARNING LAMP ON WILL CAUSE ENGINE DAMAGE. ­ PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY, SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN 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 DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED. IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT THE ENGINE FASTENING SCREWS ARE TIGHT. IN THE EVENT THAT, WHILE RIDING YOUR MOTORCYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. 13 BEFORE Braking Close throttle and apply the hand and foot brakes at the same time. When driving on sandy, wet or slippery ground use mainly the rear wheel brake. Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. When driving downhill, use the braking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to brake so much and the brakes will not overheat. WARNING ­ DELAYED ­ ­ BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE. IN THIS CASE, REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY. DELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY ROADS. IN THIS CASE, REPEATEDLY APPLY THE BRAKES TO REMOVE THE DIRT. WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL. Shifting/Riding You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, road gradient, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever and shift to the next higher gear. Let clutch lever go again and open throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm. When you reach full speed through turning the throttle grip all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Never open the throttle wider than the engine can handle. Excessive turning of the throttle grip will increase full consumption. By shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throttle or shift down again. If the engine is killed f.ex. at a crossing, simply pull the clutch lever and start. It is not necessary to switch the gear to NEUTRAL. WARNING ­ AVOID ­ ­ ­ ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY ROADS. OTHERWISE, THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL. NEVER TURN THE IGNITION KEY TO POSITION OR WHILE THE MOTORCYCLE IS MOVING. AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN. A BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS STABILITY. ENGLISH 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. WARNING ­ MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED. NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS. ­ ! ­ PARK CAUTION ! ­ ­ YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD GROUND, LEVEL SURFACE) AND CAN'T TIP OVER. CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE. ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS. ENGLISH 14 35 mm NOTE REGARDING THE SIDE STAND: Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways. Make sure that the ground is solid and that your motorcycle is standing securely. Just in case, you can shift into first gear. ! THE CAUTION ! SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE. THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTORCYCLE, THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND. Refueling In the condition at delivery, the LC4 engine requires leaded or unleaded premium-grade fuel with at least 95 octane (ROZ). If this type of fuel is not available it is easy to change over to the pre-programmed ignition curve for 80 - 94 octane (ROZ) (see activating the ignition curve for low-octane fuel). CAUTION ! ! USE LEADED OR UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE DAMAGE WILL OCCUR. WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR'S ADVICE IMMEDIATELY. Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (ROZ) 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 . If the two connectors are connected to each other, the ignition curve for fuel having at least 95 octane (ROZ) is activated. If you disconnect the plug and socket connection, the ignition curve for fuel having 80 - 94 octane (ROZ) is activated. Although this causes the engine to lose some of its power output, it prevents poor glow ignitions and engine damage. ! IF CAUTION ! FUEL HAVING AT LEAST 95 OCTANE (ROZ) IS NOT AVAILABLE, THE IGNITION CURVE FOR 80 - 94 OCTANE (ROZ) MUST BE ACTIVATED TO PREVENT ENGINE DAMAGE. 1 15 ENGLISH PERIODIC MAINTENANCE SCHEDULE 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 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 1st Service after 1000 km 640 Duke II 2nd Service after 5000 km, then every 5000 km or once a year 16 ADD-ON-PARTS CARBUTATOR ENGINE BRAKES CHASSIS 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 at least once a year every 2 years or 20000 km 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! WHEELS ENGLISH VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running. Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start after every cleaning once a year 17 ENGLISH MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING 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 SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. CAUTION ! ! ­ WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR­ WHEN ­ ­ ­ ­ ­ ­ BURETOR, ELECTRIC CONNECTORS ETC. TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IF THE MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK DO NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS. LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED. PROPERLY DISPOSE OF OIL, GREASE, FILTERS, FUEL, CLEANSERS, BRAKE FLUID, COOLING LIQUID, ETC. OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY. ALSO OBSERVE THE SAFETY REGULATIONS WHEN HANDLING THESE SUBSTANCES. UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER USED OIL CONTAMINATES 1,000.000 LITERS WATER. IF YOU UNFASTEN SELF-LOCKING NUTS, YOU HAVE TO REPLACE THEM BY NEW ONES. IF YOU UNFASTEN SCREWS AND NUTS SECURED BY LOCTITE, YOU HAVE TO REATTACH AND SECURE THEM IN THE SAME WAY. SEE TECHNICAL SPECIFICATIONS - FASTENING TORQUES ON PAGE 41. ENGLISH 18 Removing the seat 1 2 3 Put the ignition key into the lock. Turn it counter clockwise all the way to the stop to unlock the seat. Lift the rear portion of the seat, pull it backwards and disengage it from the oval head screw 1. The tool set, the battery and the main fuse are located below the seat. Additionally, there is a compartment where small items can be stored. FIXING THE SEAT: Hook the seat onto the oval head screw 1. Push the seat forward, at the same time depressing the middle section so that the retaining bracket 2 engages at the seat. Depress the rear portion of the seat until the locking bolt 3 engages. Take out the key. WARNING CHECK IF THE LOCKING BOLT IS PROPERLY ENGAGED. THE REAR PORTION OF THE SEAT MUST BE FIXED SO THAT IT CAN'T BE LIFTED. IF THE SEAT IS LOOSE, THE MOTORBIKE CAN EASILY GET OUT OF CONTROL. 4 Supporting strap for the passenger The passenger can hold on to the supporting strap 4 on the seat. Tool kit The tool kit 5 is stored below the seat. 5 Checking and adjusting the steering head bearing* Check steering head bearing for play periodicaly. To check this, put motorcycle 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. Don't tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly tap on the top triple clamp to release tension. Re-tight the five clamp screws to 15 Nm (11 ft.lb). WARNING IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE 2 1 WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL. ! IF CAUTION ! At least once a year, the steering head bearings should be greased. (e.g. Motorex Long Therm 2000) 19 Bleeder screw front fork The bleeder screws 3 should now and then be released a few turns to let overpressure, if any, escape from the interior of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical maintenance service. ! EXCESSIVE CAUTION ! PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BLEEDER SCREWS BEFORE HAVING THE SEALS REPLACED. 3 Cleaning the dust sleeves of the telescopic fork The dust-protection bellows 4 are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward. 4 Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with silicone spray or engine oil. Then, push dust-protection bellows into the outer tubes by hand. WARNING NO SILICONE OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE'S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE. ENGLISH YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, FIRSTLY THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.