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KTM 640 DUKE II 2005 User Manual

KTM 640 DUKE II 2005
50 pages
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BEDIENUNGSANLEITUNG2005
OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.50
640 DUKE II

Table of Contents

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KTM 640 DUKE II 2005 Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Displacement625 cc
Bore x Stroke101 mm x 78 mm
Compression Ratio11.5:1
CoolingLiquid cooled
Transmission5-speed
Rear SuspensionWP monoshock
Front Tire120/70 ZR17
Rear Tire160/60 ZR17
Seat Height865 mm
Torque55 Nm @ 5500 rpm
Fuel SystemCarburetor
FrameChromium-Molybdenum steel trellis
Front SuspensionWP upside-down fork
Front BrakeSingle 320 mm disc
Rear BrakeSingle 220 mm disc
Fuel Capacity11.5 l

Summary

Important Safety Information

General Safety Warnings

Key safety advice, warnings about potential dangers and damage.

Introduction to Your Motorcycle

Welcome and Manual Guidance

Congratulates owner, emphasizes reading manual for proper operation and safety.

Limited Warranty and Guarantee Information

Warranty Terms and Conditions

Details warranty coverage, service requirements, and exclusions.

Serial Number Locations

Locating Vehicle Identification Numbers

Instructions for finding the chassis and engine serial numbers.

Operation Instruments

Control Levers and Switches

Explains clutch, decompression, choke, handbrake, and combination switches.

Instruments and Ignition

Details speedometer, tachometer, indicator lamps, and ignition lock.

Starting Controls and Fuel System

Covers emergency switches, filler cap, and fuel tap operation.

Riding and Starting Mechanisms

Describes shift lever, kickstarter, foot brake pedal, and starting procedures.

Suspension Damping Adjustments

How to adjust fork and shock absorber damping.

General Tips for Starting the Motorcycle

Initial Operation, Safety, and Tires

Guidance on first ride, safety gear, riding practices, and tire preparation.

Driving Instructions

Pre-Ride Checks and Cold Engine Start

Essential checks before riding and procedure for starting a cold engine.

Riding Techniques and Braking

Starting warm engines, riding basics, shifting, and braking.

Stopping, Parking, Refueling, and Ignition Curves

Procedures for stopping, parking, refueling, and ignition curve adjustment.

Periodic Maintenance Schedule

Scheduled Maintenance Tasks and Intervals

Lists routine maintenance tasks and their recommended service intervals.

Vital Checks and Care Procedures

Owner-performed checks and care for optimal motorcycle performance.

Chassis and Engine Maintenance

Seat, Toolkit, and Battery Access

Procedures for seat removal, accessing the tool kit, and battery compartment.

Steering Head and Front Fork Service

Adjusting steering head bearing and cleaning front fork dust sleeves.

Shock Absorber and Linkage Maintenance

Adjusting spring preload, checking rear shock absorber, and lubricating linkage.

Drive Chain and Sprocket Care

Checking chain tension, wear, and performing chain maintenance.

Brake System Service

General info on disc brakes, pads, fluid, and specific service for front/rear brakes.

Wheel Removal and Tire Pressure

Procedures for wheel removal, checking damping rubbers, and tire pressure.

Battery and Fuse Maintenance

Battery care, charging, and fuse box location and function.

Lighting System Maintenance

Replacing headlight, parking light, and flasher bulbs.

Cooling System and Air Filter Service

Checking coolant level and cleaning the air filter.

Control Adjustments and Idle Speed

Adjusting clutch, choke, decompression cables, and engine idle speed.

Engine Oil and Carburetor Maintenance

Draining carburetor float chamber and checking engine oil level.

Engine Oil Change and System Bleeding

Procedure for changing engine oil, filter, screen, and bleeding the oil system.

Trouble Shooting

Engine Starting and Running Issues

Addresses problems like engine not cranking, not starting, or poor idling.

Performance and Overheating Problems

Troubleshoots issues like lack of power, high oil consumption, and engine overheating.

Electrical and Fuel System Issues

Addresses lighting failures, neutral lamp issues, and battery discharge.

Cleaning and Storage

General Cleaning and Winter Storage Procedures

Guidelines for cleaning the motorcycle and preparing it for winter storage.

Technical Specifications

Engine Specifications and Settings

Detailed technical specifications for the engine and carburetor settings.

Chassis Specifications and Torques

Technical details for frame, suspension, brakes, wheels, and fastener torque values.

Wiring Diagram

Motorcycle Electrical System Overview

Comprehensive wiring diagram for the motorcycle's electrical system.

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