KTM 640 DUKE II 2005 User manual

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

ENGLISH
1
IMPORTANT »
Please insert the serial numbers of your motorcycle in the boxes below
Frame number
Engine number
Key number
Stamp of dealer
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above
items, all without previous announcement and without giving reasons. KTM may stop manufacturing cer-
tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or
ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con-
tain extra equipment, which is not applied to standard models.
© 2005 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.
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 inopera-
tive by any person.
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.
– IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT
THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

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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 motor-
cycle 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 chas-
sis 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.
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 environmen-
tally conscious and respect the rights of others.
We wish you a lot of fun when driving !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA

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3
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »
The 640 DUKE II 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 serv-
ice 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 manipu-
lations 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.

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4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . .7
Emergency OFF tip switch, light switch, starter tip 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 sea . . . . . . . . . . . . . . . . . . . . . . . . . .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, oil filter and screen filter change,
bleeding of the oil system . . . . . . . . . . . . . . . . . . . .35
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .37
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
CONSERVATION FOR WINTER OPERATION . . . . . . . . .40
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
RE-INITIATION AFTER TIME OF STORAGE . . . . . . . . . .40
TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . .41
TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . .42
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .44
WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . .appendix

SERIAL NUMBER LOCATIONS »
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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 1.
Clutch lever
The clutch lever [1] is fitted on the left hand side of the handle bar. The adjust-
ing screw [A] is used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
The clutch is hydraulically actuated and adjusts itself automatically.
Hand decompression lever
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 does-
n’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 carbu-
retor 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.
OPERATION INSTRUMENTS »
3
2
1
A

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6
OPERATION INSTRUMENTS »
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
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 dis-
play.
Tachometer
The tachometer [3] shows the engine speed in revolutions per minute (rpm).
Do not push the engine into the red 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 con-
trol 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
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
2
3
4
A
B
C

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7
OPERATION INSTRUMENTS »
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
The horn is sounded with button [3].
The light signal (high beam) is actuated with button [4].
Emergency OFF tip switch, light switch, starter tip switch
The emergency off switch [5] 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 cir-
cuit are interrupted).
The light switch [6] has 3 positions:
Light off
Parking light on
Headlight on
Use the starter tip switch [7] to operate the electric starter.
Filler cap
The filler cap [8] can 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
4
4
2
3
5
7
8
6

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8
OPERATION INSTRUMENTS »
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 posi-
tion. 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 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.
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.
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).
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
1
2,3,4,5
N

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9
OPERATION INSTRUMENTS »
Compression damping of fork
Hydraulic compression damping determines the reaction when the fork is com-
pressed. 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 05187A03 . . . .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 05187A03 . . . .16 clicks
Compression damping of shock absorber
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 01187A05 . . . .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 01187A05 . . . .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
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »
Instructions for initial operation
– Make sure the work for the „pre-delivery inspection“ was per-
formed by your authorized KTM workshop. The DELIVERY CER-
TIFICATE and SERVICE MANUAL will be handed over when you
pick up your vehicle.
– 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 possi-
ble 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 motorcy-
cle 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 man-
ufacturers 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, tilt-
ing 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 changes in the weight distribution.
Read the section on „Accessories and payload“ when carrying
luggage.
– Pay attention to running in instructions.
Running in
Even finely machined surfaces of engine parts have rougher sur-
faces than parts that slide on each other for a long time. Therefore,
every engine must be run in. For this reason, do not demand max-
imum 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 revolu-
tions per minute must not go exceed 4800 rpm. Once you have
run your engine in for 1000 km (620 miles), you may push it to
its 8500 rpm limit, i.e. up to the red zone indicated in the tachome-
ter. 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.
– 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 DRIV-
ERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
– THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED
WITH TIRES THAT HAVE THE SAME PROFILE TYPE.
– NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY
MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PURPOSE,
RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DUR-
ING THE FIRST 200 KILOMETERS WITH NEW TIRES, TILTING THE
VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE
PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL
GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN.
– DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS
OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY
OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED
WHEN THE TIRES ARE WARM.
– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND
TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZ-
ARDS 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.
Accessories and payload
Accessory parts and baggage can significantly decrease a motor-
cycle's driving stability. Please observe the following warnings.
– ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR
EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPER-
TIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER
THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHI-
CLE’S DRIVING PROPERTIES.
– FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTOR-
CYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND
REAR WHEELS AND ON THE LEFT AND RIGHT.
– BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND;
LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.
– A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING
AND CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT
YOUR DRIVING SPEED ACCORDINGLY.
– 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.

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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.
3 CHAIN
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.
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 driv-
ing 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 min-
imum 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 lin-
ings. Brake linings measured at their thinnest point should not be less
than 1 mm since extremely worn linings can lead to brake failure.
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.

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12
DRIVING INSTRUCTIONS »
Starting when the engine is cold
1 Open the fuel tap.
2 Turn on the ignition.
3 Switch the gear to neutral (green lamp [1] lights).
4 Turn on the emergency OFF switch [2].
5 Operate the choke lever [3].
6 Operate the starter button [5] without accelerating.
7 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.
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.
– 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.
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“ sec-
tion or contact a KTM dealer.
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
STARTER TIP SWITCH IS OPERATED EVEN THOUGH SUFFICIENT ELEC-
TRIC 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 Open the fuel tap.
2 Turn on the ignition.
3 Switch the gear to neutral (green lamp [1] lights).
4 Turn on the emergency OFF switch [2].
5 Operate the starter button [5] without accelerating.
6 Swing up the sidestand [4].
7 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.
1
2
5
3
4
6

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13
DRIVING INSTRUCTIONS »
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 kick-
starter hard all the way.
– 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 KICK-BACK HAZARD.
– CHECK FOR POWER TRANSMISSION AT TEMPERATURES BELOW
0°C (32°F) BEFORE YOU ACTUATE THE KICKSTARTER. IF YOU
DEPRESS THE KICKSTARTER WITHOUT FEELING ANY RESISTANCE,
POWER IS NOT BEING TRANSMITTED. THIS COULD CAUSE INJURIES.
BEFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE
SIDE STAND.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly release
the clutch lever and open throttle at the same time.
– BEFORE 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.
– ALWAYS TURN ON THE LIGHT WHEN YOU DRIVE. OTHER DRIVERS
WILL BE ABLE TO SEE YOU MUCH SOONER.
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.
– AVOID ABRUPT LOAD CYCLES IN CURVES AND ON WET OR SLIP-
PERY 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.
– HIGH 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 GIV-
ING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRE-
CAUTIONS 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 TROU-
BLE. 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 DEAL-
ERS 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 IMME-
DIATELY, 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.
– 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.
– DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS.
– IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE
PEDAL FEELS „SPONGY“ (TOO MUCH PLAY), THIS IS AN INDICA-
TION 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.

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14
DRIVING INSTRUCTIONS »
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.
– MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-
NING. 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 HAZ-
ARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.
– PARK 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 CAR-
BURETOR 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.
NOTE REGARDING THE SIDE STAND:
Use your foot to kick side stand forward up to the stop and lean the motorcy-
cle 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 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 pre-
mium-grade fuel with at least RON 95 (USA = Premium RON 91).
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 (RON) (see activating the ignition
curve for low-octane fuel).
USE LEADED OR UNLEADED PREMIUM-GRADE 95 OCTANE (RON) FUEL. IF USING
LOWER OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE
ENGINE DAMAGE WILL OCCUR.
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 GASO-
LINE 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.).
35 mm

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15
DRIVING INSTRUCTIONS »
Activating the ignition curve for low-octane fuel
If you are traveling to a country where fuel having at least 95 octane (RON)
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 (RON) is activated.
If you disconnect the plug and socket connection, the ignition curve for fuel
having 80 - 94 octane (RON) is activated. Although this causes the engine
to lose some of its power output, it prevents poor glow ignitions and engine
damage.
IF FUEL HAVING AT LEAST RON 95 (USA = PREMIUM RON 91) IS NOT AVAILABLE,
THE IGNITION CURVE FOR 80 - 94 OCTANE (RON) MUST BE ACTIVATED TO PRE-
VENT ENGINE DAMAGE.
1

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16
PERIODIC MAINTENANCE SCHEDULE »
A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
1st Service
after
1000 km
2nd Service after
5000 km, then
every 5000 km
or once a year
ENGINE
Change engine oil, oil filters, and fine filter z z
Clean oil screens and magnet of drain plug z z
Check oil lines for damage and kink-less arrangement z z
Check and adjust spark plug, replace it every 10,000 km z
Check and adjust valve clearance z z
Check engine fastening screws for tight fit z z
Make sure all engine screws accessible from the outside are screwed tight z z
CARBURATOR
Check carburetor connection boots for cracks and leaks z
Check idle setting z z
Check bleeder hoses for damage and kink-free arrangement z z
ADD-ON-PARTS
Check cooling system for leaks, antifreeze protection z z
Check radiator fan for proper function z
Check exhaust system for leaks and suspension z z
Check actuating cables for damage, smooth operation, and kink-less arrangement, z z
adjust and lubricate
Check fluid level of the clutch master cylinder z z
Clean air filter and air filter box z
Check cables for damage and kink-less arrangement z
Check headlamp adjustment z
Check electrical system for function (low/high beams, stop light, turn indicators, z z
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Make sure all screws and nuts are tight z z
BRAKES
Check brake fluid level, lining thickness, and brake discs z z
Check brake lines for damage and leaks z z
Check/adjust smooth operation, free travel of handbrake/foot brake levers z z
Check screws of brake system for tight fit z z
CHASSIS
Check suspension strut and fork for leaks and proper function z z
Check O-ring of suspension strut for wear z
Clean dust sleeves z
Bleed fork legs z z
Check swinging-fork pivot z z
Check/adjust steering-head bearing z z
Service eccentric for chain tension z
Lubricate reversing lever z
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, z z
swinging-fork pivot, reversing lever, suspension strut)
WHEELS
Check tire condition, inflation pressure, and rim condition z z
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension z z
Lubricate chain z z
Check wheel bearings and jerk damper for play z
640
DUKE II
2005
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!

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17
PERIODIC MAINTENANCE SCHEDULE »
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
at least
once a year
every 2 years
or 20000 km
Perform complete fork maintenance z
Perform complete suspension strut maintenance z
Perform complete reversing lever maintenance z
Replace glass-fiber yarn packing of the silencers z
Clean and lubricate steering-head bearing and sealing elements z
Clean and adjust the carburetor z
Treat the electrical contacts and switches with contact spray z
Treat battery connections with contact grease z
Change the brake fluid z
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
before each
start
after every
cleaning
once
a year
Check oil level z
Check brake fluid level z
Check brake pads for wear z
Check lighting system for proper operation z
Check horn for proper operation z
Lubricate and adjust actuating cables and nipples z
Bleed fork legs in regular intervals z
Remove and clean fork dust sleeves in regular intervals z
Clean and lubricate chain as necessary z
Check chain tension z z
Clean air filter and filter box z
Check tire pressure and wear z
Check coolant level z
Check fuel lines for leaks z
Drain float chamber z
Check all control elements for smooth running z
Check brake performance z z
Treat exposed metal components (except for the braking and exhaust z
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray z
Check all bolts, nuts, and hose clamps for their tight fit z

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18
MAINTENANCE WORK ON CHASSIS AND ENGINE »
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 SERV-
ICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.
– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE
THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC.
– WHEN 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.
– IF YOU UNSCREW ANY SCREWED CONNECTIONS WITH SELF-LOCKING NUTS, THEY MUST BE REPLACED WHEN MOUNTING. IF NO SELF-
LOCKING NUTS ARE AVAILABLE, APPLY LOCTITE 243 TO THE THREAD. THE SCREWS AND NUTS MUST BE REPLACED IF THE THREAD IS
DAMAGED.
– ALL SCREWS AND NUTS MUST BE TIGHTENED TO THE SPECIFIED TORQUE FIGURES USING A TORQUE WRENCH. IF SCREWS OR NUTS
ARE NOT ADEQUATELY TIGHTENED, THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO GO OUT OF CONTROL WHILE YOU DRIVE.
TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS.
– 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.
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 [2] engages at the seat.
Depress the rear portion of the seat until the locking bolt [3] engages.
Take out the key.
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.
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.
1
2
3
4
5

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19
MAINTENANCE WORK ON CHASSIS AND ENGINE »
Checking and adjusting the steering head bearing*
Check steering head bearing for play periodicaly. To check this, put motorcy-
cle 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).
IF THE 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.
IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI-
ODS, 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 [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 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 [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.
11 1
2
3
4
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil
them thoroughly with Universal oil spray (Motorex Joker 440) or engine oil.
Then, push dust-protection bellows into the outer tubes by hand.
NO 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.