KTM 640 DUKE II 2003 User manual

OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2003
BEDIENUNGSANLEITUNG
Art.Nr. 3.210.58 2/2003
640 DUKE II

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1
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:

WARNING

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
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 mainten-
ance, 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.
COMSUMER INFORMATION FOR AUSTRALIA ONLY
KTM S PORTMOTORCYCLE AG 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 SUBSTI -
TUTING THEM WITH OTHERS . I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I NTHE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .

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2
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 !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3
In accordance with the international quality management
ISO 9001 standard, KTM uses quality assurance processes
that lead to the highest possible product quality.
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.

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4
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
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
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
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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
INDEX

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5
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.
Engine number, engine type
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.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
Clutch lever
The clutch lever 1is fitted on the left hand side of the handle bar. The
adjusting screw Ais used to change the original position of the clutch lever
(see maintenance work on chassis and engine).
Hand decompression lever
The hand decompression lever 2is 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 3is pulled backwards, a bore is opened in the car-
buretor 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.
2
3
1
A

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6
Hand brake lever
The hand brake lever 1is 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
The mileage indicator Ain the speedometer 2indicates overall mileage.
The day mileage indicator Bcan 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.
Tachometer
The tachometer 3shows the engine speed in revolutions per minute (rpm).
Do not push the engine into the orange zone, which begins at 8500 rpm.
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 .
1
A
2
B
C
3
4

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7
Combination switch
The rocker switch LIGHTS 1actuates the high beam or low beam.
= High-beam light
= Low-beam light
The indicator switch 2returns to central position after actuation.
Press flasher switch towards switch housing to switch off the flasher.
The horn is sounded with button 3.
The light signal (high beam) is actuated with button 4.
Starter tip switch, emergency OFF tip switch, light switch
Use the starter tip switch 5to operate the electric starter.
The light switch has 3 positions:
= Light off
= Parking light on
= Headlight on
The emergency off switch 6is 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 7can be locked and is provided with a fuel evaporation con-
trol 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.
1
2
3
4
5
6
7
4

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8
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.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IFTHE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE.
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 bet-
ween first and second gear.
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can
be swivelled.
Foot brake pedal
The foot brake pedal is located in front of the right footrest. The basic posi-
tion can be adjusted to the seat position (see maintenance work).
2,3,4,5
1
N
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
OFF ON RES

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9
Compression damping of fork
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 readju-
sted at the adjusting screws 1located at the fork leg. Turn it clockwise to
increase damping, and counterclockwise to reduce damping during com-
pression.
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
Rebound damping of fork
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
With the knob 3the degree of damping of the compression can be adju-
sted 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 4the 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
Seat lock
The seat is secured by the lock on the side of the seat 5
1
1
2
2
3
4
5

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10
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 sur-
face 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; dis-
tribute 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.
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 maxi-
mum 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.

WARNING

–W
EAR 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.
–A
LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
–DONOT 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’SDRIVING
PROPERTIES.
–T
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.
–O
BSERVE 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.
–A
DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–D
RIVE 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.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

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11
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.
2 FUEL
Check that there is sufficient fuel in the tank.
3CHAIN
A loose chain can fall off; an extremely worn chain can tear, and insuffi-
cient lubrication can result in unnecessary wear to the chain and rear
sprockets.
4TIRES
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 dri-
ving performance.
5BRAKES
Check correct functioning of the braking system. Check for sufficient
brake fluid in the reservoir. If the level of brake fluid falls below the mini-
mum 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

IFTHE 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’TRIDE 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.
7COOLING 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.

ENGLISH
12
Starting when the engine is cold
1Open the fuel tap.
2Turn on the ignition.
3Switch the gear to neutral (green lamp 1lights).
4Turn on the emergency OFF switch 2.
5Operate the choke lever 3.
6Operate the starter button 5without accelerating.
7If the engine starts, push the choke lever back a little bit, as soon as the
engine runs unevenly.
8Swing up the sidestand 4.
9Switch on the light before setting off.

WARNING

DONOT 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.
!
CAUTION
!
–MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5
SECONDS BEFORE TRYING AGAIN.
–D
ON’TRIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’TREV 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.
IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STAR-
TER 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 „Trouble-
shooting“ section or contact a KTM dealer.
THE ELECTRIC STARTER DOESN’T CRANK THE ENGINE WHEN THE STAR-
TER 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
1Open the fuel tap.
2Turn on the ignition.
3Switch the gear to neutral (green lamp 1lights).
4Turn on the emergency OFF switch 2.
5Operate the starter button 5without accelerating.
6Swing up the sidestand 4.
7Switch 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.
1
4
2
3
6
5

ENGLISH
13
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

–I
FYOU 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 KICK-
BACK HAZARD.
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

B
EFORE YOU START OFF
, CHECK THAT THE SIDE STAND HAS BEEN SWUNG
RIGHT UP TO THE TOP
. I FTHE STAND DRAGS ON THE GROUND , THE
MOTORCYCLE CAN GO OUT OF CONTROL
.
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

–A
VOID ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIPPERY
ROADS. OTHERWISE, THE MOTORCYCLE COULD EASILY GET OUT OF
CONTROL.
–N
EVER TURN THE IGNITION KEY TO POSITION OR WHILE THE
MOTORCYCLE IS MOVING.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
–ABENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO
STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS
STABILITY.
!
CAUTION
!
–HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WERECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
ACHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN
THIS RESPECT NEED BE TAKEN.
–S
HIFT TO THE NEXT HIGHER GEAR BY 8500 RPM AT THE LATEST.
ENGINE SPEEDS IN THE RED RANGE MUST STRICTLY BE AVOIDED.
–
N EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A
LOWER GEAR
. T HE ENGINE WILL OVERSPEED , DAMAGING THE VALVES .
I
NADDITION ,
THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL
.
– L ONG WHEELIE DRIVING CAUSES THE OIL PRESSURE TO DROP . T HE OIL
PRESSURE WILL AUTOMATICALLY INCREASE AS SOON AS YOU DRIVE ON
NORMALLY
. D OING WHEELIES FOR A LONG TIME WILL DAMAGE YOUR
ENGINE
.
–I
FTHE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE
YOU ARE DRIVING, THIS INDICATES COOLING SYSTEM TROUBLE. IMME-
DIATELY STOP AND TURN OFF THE ENGINE. DRIVING WITH THE WAR-
NING 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.
– DONOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COO-
LING SYSTEM. HOWEVER, CALL ON ONE OF KTM’S DEALERS AS
SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED.
–I
FANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT
THE ENGINE FASTENING SCREWS ARE TIGHT.
–I
NTHE 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.
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

–D
ELAYED BRAKE ACTION MUST BE EXPECTED DUE TO WET BRAKE DISKS
DURING RAINY WEATHER OR AFTER CLEANING OF THE MOTORCYCLE.
INTHIS CASE, REPEATEDLY APPLY THE BRAKES UNTIL THEY ARE DRY.
–D
ELAYED BRAKE ACTION CAN ALSO OCCUR ON SALTED OR DIRTY
ROADS. INTHIS CASE, REPEATEDLY APPLY THE BRAKES TO REMOVE THE
DIRT.
–W
HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER
AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEA-
KER THE BRAKING EFFECT. INEXTREME CASES, THE ENTIRE BRAKING
SYSTEM CAN FAIL.

ENGLISH
14
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

–M
OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE
ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK ABSOR-
BERS CAN BECOME VERY HOT. DONOT TOUCH ANY OF THESE PARTS AFTER OPERA-
TING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT
LIKELY TO TOUCH IT AND GET BURNED.
–N
EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE
TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.
!
CAUTION
!
–PARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD
GROUND, LEVEL SURFACE) AND CAN’TTIP OVER.
–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CARBURETOR
CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE.
–A
LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT
IT CANNOT BE USED BY UNAUTHORIZED PERSONS.
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.
!
CAUTION
!
THE 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-pro-
grammed ignition curve for 80 - 94 octane (ROZ) (see activating the igni-
tion curve for low-octane fuel).
!
CAUTION
!
USE LEADED OR UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IFUSING 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. DONOT 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. IFGASOLINE IS SWALLOWED OR SPLASHED IN THE EYES,
SEEK A DOCTOR’SADVICE IMMEDIATELY.
Fuel expands when its temperature rises. Therefore do not fill the tank to
the top (see fig.).
35 mm

ENGLISH
15
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 1on 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.
!
CAUTION
!
IF 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

ENGLISH
16
PERIODIC MAINTENANCE SCHEDULE
1st Service
after
1000 km
2nd Service after
5000 km, then
every 5000 km or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S ERVICE 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!
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 ●
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 ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBUTATOR
ENGINE
640 Duke II
every 2 years
or 20000 km
at least
once a year

ENGLISH
17
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 ●
once a yearafter every
cleaning
before each
start

ENGLISH
18
Removing the seat
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 2engages at the seat.
Depress the rear portion of the seat until the locking bolt 3engages.
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’TBELIFTED. IFTHE SEAT IS LOOSE, THE MOTORBIKE CAN
EASILY GET OUT OF CONTROL.
Supporting strap for the passenger
The passenger can hold on to the supporting strap 4on the seat.
Tool kit
The tool kit 5is stored below the seat.

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
!
–W
HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-
BURETOR, ELECTRIC CONNECTORS ETC.
–WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IFTHE
MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK
–DONOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WOR-
KING LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–P
ROPERLY 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.
–U
NDER 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 SPECIFICATI-
ONS - FASTENING TORQUES ON PAGE 41.
MAINTENANCE WORK ON CHASSIS AND ENGINE
1
2
3
4
5

ENGLISH
19
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 1of the top triple clamp and turn
steering stem bolt clockwise 2until 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

I FTHE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY , THE MOTORCYCLE
WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL
.
!
CAUTION
!
IFYOU 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.
At least once a year, the steering head bearings should be greased.
(e.g. Motorex Long Therm 2000)
Bleeder screw front fork
The bleeder screws 3should 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.
!
CAUTION
!
EXCESSIVE 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.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 4are 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.
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with silicone spray or engine oil. Then, push dust-pro-
tection bellows into the outer tubes by hand.

WARNING

NOSILICONE OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD
CONSIDERABLY REDUCE THE TIRE'SROAD GRIP AND THE BRAKING EFFECT OF THE FRONT
BRAKE.
2
4
1
3