KTM 640 DUKE II 2001 User Manual

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OWNERS HANDBOOK

2001

BEDIENUNGSANLEITUNG

640 DUKE II

Art.Nr. 3.205.99 11/2000

Important Notes3
- Engine Number3
- Table of Contents5
Serial Number Locating6
- Cassis Number6
- Engine Number, Engine Type6
Operation Instruments6
- Clutch Lever6
- Hand Decompression Lever6
- Choke Lever6
- Hand Brake Lever7
- Speedometer7
- Tachometer7
- Indicator Lamps7
- Ignition Lock, with 4 Switch Position8
- Ignition Lock with 3 Switch Position8
- Combination Switch8
- Emergency off Button8
- Emergency off Switch9
- Filler Cap9
- Fuel9
- Fuel Tap9
- Shift Lever10
- Kickstarter10
- Foot Brake Pedal10
- Compression Damping of Fork10
- Rebound Damping of Fork10
- Compression Damping of Shock Absorber11
- Rebound Damping of Shock Absorber11
- Seat Lock11
- Supporting Strap for the Passenger11
Driving Instructions12
- Kickstart Instructions14
- Starting off14
- Stopping and Parking15
- Periodic Maintenance Schedule16
Lubrication and Maintenance Schedule16
Maintenance Work on Chassis and Engine18
Tool Kit18
Checking and Adjusting the Steering Head Bearing18
Changing the Spring Preload of the Shock Absorber19
Checking the Rubber Ring on the Shock Absorber19
Lubricate Rear Shock Absorber Linkage19
Checking Chain Tension20
Correcting Chain Tension20
Chain Wear20
Chain Maintenance21
Maintaining Chain Tension Eccentrics21
General Information about KTM Disc Brakes21
Changing the Basic Position of the Handbrake Lever22
- Checking of Brake Fluid Level - Front Brake22
- Refilling the Front Brake Fluid Reservoir22
- Checking the Front Brake Pads23
- Changing the Basic Position of the Brake Pedal23
- Checking the Rear Brake Fluid Level23
- Refilling the Rear Brake Fluid Reservoir23
- Checking the Rear Brake Pads24
- Dismounting and Mounting the Front Wheel24
- Dismounting and Mounting the Rear Wheel24
- Checking the Damping Rubbers in the Rear Wheel25
- Tires, Air Pressure25
- Battery26
- Charging the Battery26
- Main Fuse27
- Fuses for Indivitual Power-Consuming Units27
- Opening the Headlight Mask27
- Headlight Range Adjustment28
- Headlight - Replacing the Bulbs28
- Parking Light - Replacing the Bulb28
- Flasher - Replacing the Bulbs28
- Stop Light and Tail Light - Replacing Bulb29
- Cooling System29
- Checking the Coolant Level30
- Adjusting the Clutch Cable30
- Adjusting the Choke Cable30
- Adjusting Idle Speed31
- Draining of Float Chamber of the Carburetor31
- Oil Circuit31
- Engine Oil32
- Checking Engine Oil Level32
- Change of Oil and Fine Screen Filter, Bleeding of the Oil System32
- Changing Oil Filter33
- Changing the Fine Screen Filter33
Trouble Shooting34
Cleaning37
Conservation for Winter Operation37
Storage37
- Re-Initation after Time of Storage37
Technical Specifications - Engine38
Technical Specifications - Chassis39
Head Word Index41
Appendix41
Consumer Information for Usa Only41

Questions and Answers:

R
Rebecca SkinnerSep 10, 2025
What to do if my KTM 640 DUKE II 2001 engine cranks but doesn’t start?
- K
  kgrantSep 12, 2025
  If your KTM Motorcycle engine cranks but doesn’t start, ensure the fuel tap is open and there's enough fuel in the tank. If the motorcycle has been out of operation for more than a week, drain the old fuel from the float chamber and fill it with new fuel. Fully open the throttle when starting. Clean and dry the spark plug or exchange it. Adjust spark plug electrode gap to 0,7 mm. Check for a strong spark at the spark plug. If there is no spark, disconnect the spark plug connector from the ignition cable, hold it a distance of approx. 5 mm from ground and start. If a spark now occurs, replace spark plug cap. If no spark is produced, control ignition system. Clean the plug connection and treat it with contact spray. Dismount and clean carburetor.
R
Robert JohnsonSep 12, 2025
What does it mean if the NEUTRAL lamp is not on even though the gear is in NEUTRAL on my KTM Motorcycle?
- D
  Daniel MitchellSep 12, 2025
  If the NEUTRAL lamp is not on even though the gear is in NEUTRAL on your KTM Motorcycle, it could be due to a defect indicator lamp, a defect neutral switch, or loose connections/defect cable. Replace the bulb. Connect cable to ground; neutral switch must be replaced if indicator lamp lights up. Check connections and cables.

KTM 640 DUKE II 2001 Specifications

General

Engine Type	Single-cylinder, four-stroke
Displacement	625 cc
Compression Ratio	11.5:1
Cooling	Liquid cooled
Transmission	5-speed
Front Tire	120/70 ZR17
Rear Tire	160/60 ZR17
Torque	55 Nm @ 5500 rpm
Frame	Chromoly trellis frame
Rear Suspension	WP monoshock
Front Brake	Single disc, 320 mm
Rear Brake	Single 220 mm disc, 1-piston caliper
Bore x Stroke	101 x 78 mm