20 Most Recent 2002 KTM 640 Duke 2 Questions & Answers

Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to ensure your issue has been resolved.
Try this link:
http://www.carlsalter.com/motorcycle-manuals.asp

TF

hi colin

you may use a neat lowering link for Duke like the one in the picture below.



The topic below is also applicable.

http://www.ktmforums.com/forums/duke/312-lowering-suspension-make-seat-lower.html

Else:

trimming the seat will be applicable.

regards,

i know you have to change the oil and oil filter but how often and is that the only thing different from maintance on a 2-stroke?. Im getting an 04 kx 250f any help would be great!The two most important aspects of four-stroke maintenance are frequent oil/filter changes and regular valve clearance checks/adjustments. And some four-strokes (RMZ450 for example) have a manual timing chain tensioner that must be regularly checked/adjusted. Everything else is exactly like a two-stroke.,,,

your throttle cable is improperly routed and is being pulled on!

A worn wrist pin that attaches the piston to the piston's connecting rod

That would be like riding a fixed wheel bike.Think about how you will stop and start. Only hydraulic fluid will leak. Bad idea!

Question edited for clarity. That sounds like it is just a bad connection somewhere or possibly a bad switch. Remove the battery leads and clean the lead contacts and battery posts with a wire brush. Smear with Vaseline and reconnect. Remove the starter leads and do the same. Then it could be the Starter Relay https://www.google.com/search?q=ktm+450+sx-f+starter+relay+location Or Starter Button https://www.google.com/search?q=ktm+450+sx-f+starter+button+replacement ..

personnaly I would replace cylinder with new OEM

All dirt bikes have a VIN. It is on the steering neck. https://www.google.com/search?q=vin+on+my+ktm+300 ..

Have you checked battery connections. Run switch in the correct position? Checked spark plug for debris? Just thinking out loud..

Drain oil. Use degreaser to clean area. Use JB Weld & allow to set up properly before adding oil.

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Hi, try to see this link and looking for the manual that you need. https://www.pdfmotomanual.com/manuales/ktm/eng I hope to give you an help. Luca

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Hi, most likely your cdi unit or ignition coil needs replacing.

took me a min or two of WTF-ing to see pic and realize you meant a 2-stroke motorcycle..

try replace spark plugs

It's a bad seal of the head gasket. You need a new head gasket and to scrape every particle of debris from the cylinder head and cylinder surfaces that mate with the head gasket. Use the factory specified gasket sealing compound and do a clean job - no blobs or pools of the stuff. The head gasket should lay flat on the surface of the top of the cylinder, and you have to make this surface free of grit, leftover sealant and any other foreign matter before you put the head in place and torque it down. Start with the head bolts just finger tight and then go by the manufacturer's specs for the pattern and amount of torque to be applied. Usually it is recommended that you get to the specified torque amount in stages, going around several times and repeating the torque pattern until you get that maximum rated amount. This will prevent the seal from shifting or warping and should make the gasket seal perfectly. This is the old school method of doing this job. and I have never seen this fail to produce good results. Take your time, be clean, and you will have the results you want.

Check the clutch, adjust, clean, or replace

over full sump fuel getting into sump badly worn rings allowing excessive blow by

Worn out shift dogs.