🏷️ Basic Information Identification Make: KTM Model: 640 DUKE II Year: 2003 Type: Motorcycle Market Segment: Naked Sportbike 👋 Introduction Market Position Positioning: The KTM 640 DUKE II was positioned as a light, agile, and aggressive naked sportbike, emphasizing rider engagement and street performance. Competitive Analysis Competitors: Competed with other European and Japanese naked bikes of the era, offering a distinct Austrian character. Key Features Engine Type: Liquid-cooled, four-stroke, single-cylinder LC4 engine Frame Design: Lightweight trellis frame Suspension: High-quality WP suspension components Brakes: Strong Brembo braking system Design Philosophy: Focus on rider connection, minimalist design, and raw performance 📋 Manual Details Coverage Areas Primary Coverage: Vehicle Operation, Maintenance, and Basic Adjustments Secondary Coverage: Convenience Items, Driving Controls Page Count Estimated Pages: Refer to physical manual for exact count (typically 100-200 pages for this model) Manual Type Type: Owner's Manual Purpose: Guidance for first-time owners and existing owners Language Language: English (assumed, standard for most markets) Format Format: Electronic (PDF or similar digital format) Accessibility: Readable and printable on Windows, Mac, and Linux 📖 Manual Coverage Systems Covered Engine: Basic operation and care, no in-depth repair procedures Chassis: Suspension and frame overview Brakes: Operation and basic checks Electrical System: Basic component identification, fuse information Controls: Handlebar controls, foot controls, dashboard indicators Convenience Features: Lighting, seating, storage (if applicable) Procedures Included Operation: Starting, riding, stopping procedures Maintenance: Pre-ride checks, basic cleaning, fluid level checks Troubleshooting: Basic indicator light explanations, simple issue identification Adjustments: Lever adjustments, minor control adjustments Technical Depth Depth: Owner-level, focused on safe and enjoyable operation, not in-depth mechanical repair. 📊 Manual Specifications File Format File Type: Digital Document (e.g., PDF) Searchability: Likely text-searchable if a proper PDF conversion Print Quality Print Readability: Good for printing on standard office printers Binding Type Binding: N/A (Electronic Format) Paper Type Paper Type: N/A (Electronic Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single cylinder, liquid-cooled LC4 Displacement: 625 cc (approx. 625.1 cc or 654 cc depending on specific sub-variant) Bore X Stroke: 100 mm x 80 mm (typical for this generation LC4) Compression Ratio: 11.5:1 (typical) Valve Train: OHC, 4 valves per cylinder Performance Horsepower: Approx. 50-55 hp @ 7000 rpm (depending on specific tuning) Torque: Approx. 60 Nm @ 5500 rpm (depending on specific tuning) Fuel System Fuel Delivery: Carburetor (Keihin CVK 40 or Mikuni BST 40 typical) Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication Oil Type: SAE 10W-40, JASO MA, API SG or higher 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch: Wet multi-disc clutch, hydraulically actuated Features Final Drive: Chain drive Transmission Oil Type: Refer to manual (typically same as engine oil if wet clutch system) 📐 Dimensions Exterior Length: Approx. 2120 mm (varies slightly by model year and configuration) Width: Approx. 770 mm (excluding mirrors) Height: Approx. 1150 mm (to top of windscreen/headlight assembly) Weights Dry Weight: Approx. 150 kg Wet Weight: Approx. 166 kg (with all fluids) Max Load: Refer to manual (typically rider + passenger + luggage capacity) Wheelbase Wheelbase: Approx. 1470 mm Seat Height Seat Height: Approx. 870 mm Fuel Capacity Fuel Tank Capacity: Approx. 13 Liters (including reserve) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not have standardized crash test ratings like cars) Active Features Braking System: Dual hydraulic disc brakes (front), Single hydraulic disc brake (rear) Brake Calipers: Brembo 4-piston radial caliper (front), Brembo 2-piston caliper (rear) typical Lighting: Halogen headlight, LED taillight, turn signals Passive Features Frame: High-strength trellis frame for chassis rigidity and impact absorption Tires: Sport-oriented street tires for optimal grip 💡 Technology Features Infotainment Infotainment System: N/A (No infotainment system present on this model) Driver Assistance Driver Assistance Systems: N/A (No electronic driver assistance systems) Instrumentation Dashboard Type: Analog tachometer and speedometer, with indicator lights for oil pressure, neutral, turn signals, high beam. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 6 months, whichever comes first (refer to manual for precise recommendation) Air Filter Cleaning: Every 5,000 km or as needed based on riding conditions Spark Plug Replacement: Every 10,000 - 15,000 km Valve Clearance Check: Every 10,000 - 15,000 km Fluid Specifications Engine Oil: SAE 10W-40, JASO MA, API SG or higher Coolant: Ethylene glycol based coolant (50% mixture with distilled water), antifreeze properties suitable for local climate Brake Fluid: DOT 4 Fork Oil: Refer to manual for viscosity and type (e.g., WP Suspension Fluid) Known Issues Lc4 Engine: Some earlier LC4 engines experienced issues with countershaft bearings or clutch slave cylinders. Regular maintenance is key. Electrical Connections: Ensure all electrical connections are clean and secure to prevent intermittent faults. Carburetor Tuning: Carburetors may require periodic cleaning and adjustment for optimal performance, especially at different altitudes. Filter Part Numbers Oil Filter: OEM KTM part number often 00050000040 or equivalent (e.g., Hiflofiltro HF155) Air Filter: OEM KTM part number often 59006015000...