KTM 660 SMC 2003 Owner's manual

OWNER’S MANUAL

MANUALE D’USO

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2003

BEDIENUNGSANLEITUNG

Art.Nr. 3.210.54 9/2002

660 SMC

ENGLISH

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

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

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 PRE

-

VIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING

THEM WITH OTHERS

. I

T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE 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

Attachments: Spare parts manual chassis & engine

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

©

by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3

IMPORTANT LIMITED WARRANTY AND

LIMITED GUARANTEE INFORMATION

The KTM 660 SMC is designed and constructed to resist the usual wear and
tear of normal use in competitions.
The motorcycles comply with the regulations and categories currently in
effect with the leading international motorcycle associations.

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. An improperly tuned chassis can
lead to damage and breakage of the chassis components.

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.

The SMC models are only allowed on public roads in the original
homologated (throttled) version. Without this performance restriction (i.e.

dethrottled), these models are only allowed to be driven in Supermoto
competitions but not

on public roads.

No warranty will be assumed if the bike is used in races or competitions.

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

Page

SERIAL NUMBER LOCATIONS .............................................5

Chassis number ................................................................5

Engine number, engine type.............................................5

OPERATION INSTRUMENTS ...............................................5

Clutch lever ......................................................................5

Hand decompression lever................................................5

Hand brake lever..............................................................5

Indicator lamps.................................................................6

Electronic speedometer.....................................................6

Tripmaster switch .............................................................7

Overview of tripmaster functions ...................................10

Combination switch........................................................11

Flasher switch.................................................................11

Filler cap.........................................................................11

Fuel tap..........................................................................11

Choke ............................................................................11

Hot start device ..............................................................12

Shift lever .......................................................................12

Kickstarter ......................................................................12

Foot brake pedal ............................................................12

Handlebar lock ...............................................................12

Compression damping of fork ........................................13

Rebound damping of fork ..............................................13

Compression damping of shock absorber .......................13

Rebound damping of shock absorber .............................13

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE...................................................................14

DRIVING INSTRUCTIONS ..................................................15

PERIODIC MAINTENANCE-SCHEDULE ..............................18

MAINTENANCE WORK ON CHASSIS AND ENGINE ..........20

Removal of seat..............................................................20

Tool set ..........................................................................20

Check and adjust steering head bearing .........................21

Breather plugs front fork ................................................21

Cleaning the dust sleeves of the telescopic fork ..............21

Basic suspension setup for the weight of the driver.........22

Changing the spring preloading of the shock absorber ...24

Checking rubber ring on the WP rear shock absorber .....24

Lubricate rear suspension linkage ...................................24

Checking chain tension...................................................24

Correct chain tension......................................................25

Chain maintenance.........................................................25

Chain wear.....................................................................25

General informations about KTM disc brakes..................26

Adjusting of free travel at the hand brake lever ..............27

Checking brake fluid level - front brake ..........................27

Refilling the front brake fluid reservoir............................27

Check the front brake pads ............................................27

Page

Replacing front brake pads .............................................28

Check the rear brake fluid level ......................................28

Refilling the rear brake fluid reservoir .............................28

Changing the basic position of the brake pedal ..............29

Checking the rear brake pads .........................................29

Replacing the rear brake pads.........................................29

Dismounting and mounting the front wheel...................30

Dismounting and mounting the rear wheel.....................30

Tires, air pressure............................................................31

Checking spoke tension..................................................31

Check/set distance of the magnetic sensor .....................31

Kilometers or miles .........................................................32

Setting the clock.............................................................32

Activating/deactivating the display modes......................32

Replacing headlight lamp/parking light lamp..................33

Exchanging the brake light and tail light bulb .................33

Cooling system...............................................................34

Checking the coolant level..............................................34

Cleaning air filter ............................................................35

Exhaust system...............................................................35

Adjusting the throttle cable ............................................36

Checking the adjustment of the hand decompression cable

..36

Changing the original position of the clutch lever ...........36

Checking the oil level of the hydraulic clutch ..................37

Bleeding of the hydraulic clutch......................................37

Draining the float chamber of the carburetor..................37

Carburetor – Adjust idling...............................................38

Adjusting the mixture control screw ...............................38

Checking the float level ..................................................38

Engine oil .......................................................................39

Checking the engine oil level..........................................39

Oil circuit........................................................................39

Changing the engine oil .................................................40

Changing and bleeding the microfilter............................40

Changing oil filter...........................................................41

TROUBLE SHOOTING........................................................42

CLEANING..........................................................................44

CONSERVATION FOR WINTER OPERATION ....................44

STORAGE ...........................................................................44

Re-initation after time of storage....................................44

TECHNICAL SPECIFICATIONS - ENGINE ...........................46

TECHNICAL SPECIFICATIONS - CHASSIS...........................48

HEAD WORD INDEX..........................................................50

WIRING DIAGRAMME ..........................................APPENDIX

Index

ENGLISH

5

Chassis number

The chassis number is stamped on the right side of the steering head tube.
Write this number into the relevant area 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 chain sprocket. Write this number into the relevant
area on page 1.

Clutch lever

The clutch lever 1 is located on the left side of the handlebar. The
adjusting screw

A is used to change the original position of the clutch lever

(see maintenance work on chassis and engine).

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
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.

Hand brake lever

The hand brake lever is mounted on the right side of the handle bar and
actuates the front wheel brake.
The standard position of the hand brake lever can be adjusted with the
adjusting screw (see maintenance work).

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

2

1

A

ENGLISH

6

Indicator lamps

The green control lamp 1 flashes when the indicator is working in
the same rhythm as the flashing indicator.

The blue control lamp

2 lights up when the high beam is on.

Electronic speedometer

The electronic speedometer display is activated as soon as the engine is
switched on and the motorcycle starts to move.
The engine must be started in order for the speedometer to be supplied
with electricity from the generator. The display is not activated until the
front wheel has made 1 revolution (impulse for speedometer).

TEST
All of the display elements will light up for 1 second for the function test.

WS (wheel size)
The display will change and briefly show the diameter of the front wheel in
millimeters.
If the front wheel does not turn, the display will automatically change to the
SPEED/H mode.
If the front wheel turns, the display will automatically change to the SPEED
/ODO mode.

SPEED/H (hours) display mode

When you stop driving and no impulses are sent from the wheel sensor, the
display mode will automatically change from SPEED/ODO to SPEED/H. H
shows the operating hours. The operating hour counter starts to count as
soon as you start the engine. The displayed figure cannot be cleared.
Service intervals are indicated in operating hours for some KTM offroad
motorcycles, making the operating hour counter a very practical function.

SPEED/ODO display mode

The SPEED/ODO mode shows the speed and the total kilometers traveled.
When the front wheel stops turning, the display will automatically change
to the SPEED/H mode.
The information will disappear in the display when the front wheel stops
turning for 1 minute.

2

1

ENGLISH

7

Tripmaster switch

The switch has 3 buttons: MODE, + (plus) and – (minus).
The switch can also be mounted on the outer end of the handlebar with a
clamp (SP.NO. 583.14.069.350).



WARNING



D

O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR

ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN
ACCIDENT

.

Electronic speedometer functions provided by the Tripmaster
switch

The display modes on the electronic speedometer will change in the
following order. If not, please read the chapter "ACTIVATING AND
DEACTIVATING THE DISPLAY MODE."

SPEED/ODO display mode

SPEED displays the speed in KPH or MPH. The displayed figure cannot be
cleared.

ODO displays the kilometers or miles traveled. The displayed figure cannot
be cleared.

+

BUTTON no function

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to change to the next mode

SPEED/MAX display mode

MAX displays the maximum speed. It is always active.

+

BUTTON no function

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to reset the MAX figure to 0

SPEED/LAP display mode

LAP displays the stopped lap time in hours, minutes and seconds.

+

BUTTON Starts and stops the stop watch. The lap time is not reset to 0.

– BUTTON Stops the running stop watch, stores the lap time and restarts

the stop watch. The time is reset to 0. A total of 10 lap times
can be stored and read in the SPEED/LAP display mode. To
clear all of the stored lap times, hold the MODE button for 3
seconds in the SPEED/LAP mode.

press the MODE

BUTTON to change to the next mode

If no lap time is stored or the motorcycle is driving, the LAP/LAP
mode will be skipped.

press and hold the MODE

BUTTON 3 SECONDS to reset the LAP figure and all

stored lap times to 0

LAP/LAP display mode

The lap number is shown at the top and the lap time in hours, minutes and
seconds at the bottom of the display.
If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will
be skipped.
Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the
stored lap times.

+

BUTTON changes to the next lap time.

– BUTTON no function
press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to change to the next mode

MODE

–

+

ENGLISH

8

SPEED/CLK (clock) display mode

CLK will display time in hours, minutes and seconds.

+ BUTTON no function
–

BUTTON no function

press the MODE

BUTTON to change to the next mode.

press and hold the MODE

BUTTON 3 SECONDS to set the time in the menu

(see SETTING THE CLOCK)

SPEED/H (hours) display mode

When you stop driving and no impulses are sent from the wheel sensor, the
display mode will automatically change from SPEED/ODO to SPEED/H. H
shows the operating hours. The operating hour counter starts to count as
soon as you start the engine. The displayed figure cannot be cleared.
Service intervals are indicated in operating hours for some KTM offroad
motorcycles, making the operating hour counter a very practical function.

+

BUTTON no function

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to change to the SETUP mode

(see REVEALING/CONCEALING functions).

SPEED/TRP1 (trip 1) display mode

The TRP1 trip meter is always active and counts to 999.9. It is used to
measure the length of a trip or the distance between 2 refueling stops.
TRP1 is linked to AVS1 and STP1. The calculation of these figures is
activated by the first impulse received from the wheel sensor (when the
front wheel starts to turn) and stops 3 seconds after the last impulse is
received (when the front wheel has stopped).
The TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing

999.9.

+ BUTTON no function
–

BUTTON no function

press the MODE

BUTTON to change to the next mode.

press and hold the MODE

BUTTON 3 SECONDS to automatically reset the

TRP1, AVS1 and STP1 figures to 0.

SPEED/AVS1 (average speed 1) display mode

AVS1 is always active and shows the average speed based on the TRP1 and
STP1 figures. The calculation of this figure is activated by the first impulse
received from the wheel sensor and stops 3 seconds after the last impulse is
received.

+

BUTTON no function

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and

STP1 figures to 0.

SPEED/STP1 (stop 1) display mode

STP1 shows the traveling time based on TRP1 and continues to count
whenever it receives impulses from the wheel sensor. The calculation of this
figure is activated by the first impulse received from the wheel sensor and
stops 3 seconds after the last impulse is received.

+

BUTTON no function

– BUTTON no function
press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to reset the TRP1, AVS1 and

STP1 figures to 0.

ENGLISH

9

SPEED/TRP2 (trip 2) display mode

The TRP2 trip meter is always active and counts to 999.9. Contrary to
TRP1, the displayed figure can be changed using the + and – buttons. This
is a very useful function for trips taken according to a roadbook.
TRP2 is activated by the first impulse received from the wheel sensor and
stops automatically 3 seconds after the last impulse is received.

+

BUTTON increases the TRP2 figure

–

BUTTON decreases the TRP2 figure

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to reset TRP2 to 0

SPEED/AVS2 (average speed 2) display mode

AVS2 shows the average speed based on the TRP2 and STP2 figures. The
calculation of this figure is activated by the first impulse received from the
wheel sensor and stops 3 seconds after the last impulse is received.
The displayed figure will deviate from the actual average speed if TRP2 was
changed manually or if STP2 was not stopped after the trip.
+

BUTTON no function

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to change to the next mode

SPEED/STP2 (stop 2) display mode

STP2 is a manual stop watch. Start the stop watch by pressing the + but­ton, press again to hold. Press again to continue timing.
Press the MODE button to change to the next mode. The STP2 display will
blink in the other modes if STP2 continues to run in the background. To
stop STP2, return to the SPEED/STP2 mode and press the + button.

+

BUTTON starts and stops the stop watch

–

BUTTON no function

press the MODE

BUTTON to change to the next mode

press and hold the MODE

BUTTON 3 SECONDS to reset STP2 figures to 0

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10

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

no function

no function

starts / stops LAP

figure LAP remains

next figure

no function

no function

no function

no function

no function

increases TRP2 figure

no function

starts / stops STP2

Press

+

Display

SPEED / ODO

SPEED / MAX

SPEED / LAP

LAP / LAP

SPEED / CLK

SPEED / H

SPEED / TRP1

SPEED / AVS1

SPEED / STP1

SPEED / TRP2

SPEED / AVS2

SPEED / STP2

OVERVIEW OF TRIPMASTER FUNCTIONS

Standing motorcycle

Driving motorcycle

Press –

Press MODE Hold MODE for 3 sec

no function

no function

stops LAP, stores LAP

figure, resets LAP to 0

no function

no function

no function

no function

no function

no function

decreases TRP2 figure

no function

no function

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

next display mode

no function

resets MAX to 0

clears all LAP figures

next display mode

set clock menu

display setup menu

resets TRP1, STP1 and

AVS1 to 0

resets TRP1, STP1 and

AVS1 to 0

resets TRP1, STP1 and

AVS1 to 0

resets TRP2 to 0

next display mode

sets STP2 to 0

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11

Combination switch

The light switch has 3 switch positions.

A = Light off
B = Low beam light
C = High beam light

The red short circuit button

1 serves to switch off the engine. Leave the

switch pressed, until the engine stops. With the button

2 the horn will

sound.

Flasher switch

The flasher switch is a separate unit and is mounted on the left portion of
the handlebar.
The wire harness is designed in a way that whenever you want to use your
bike off-road, you can dismount the entire turn indicator system without
affecting the function of the remaining electrical system.

Flasher left

Flasher right

Filler cap

To open filler cap: Turn the filler cap counter-clockwise.
To close filler cap: Screw on the filler cap clockwise.

Install tank breather hose

3 without kinks.

Fuel tap

OFF

In this position the fuel tap is closed. No fuel may flow to the carburetor.

ON When using the motorcycle, the rotating handle 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 tank, approximately 2,5 liters, cannot be tapped until the

rotating handle is turned to the RES position. Fill the tank as soon as
possible and remember to turn the rotating handle back to the ON
position so that you will have backup fuel next time, too.

Choke

If you pull the choke button 4 out as far as possible, a bore in the
carburetor will be opened through which the engine may take in additional
fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts.
To deactivate the choke, push the choke button back into its basic position.

A

B

2

RES

ON

OFF

1

C

3

4

S

E

R

F

F

O

S

E

R

F

U

E

L

N

O

F

U

E

F

L

F

O

N

O

S

E

R

F

F

O

O

F

U

E

L

N

ENGLISH

12

Hot start device

If you pull the hot start device 1 out as far as possible, a bore in the
carburetor will be opened through which the engine may take in additional
air. The result is a „lean“ fuel-air mixture of the type needed for hot starts.
To deactivate the hot start device, push the hot start button back into its
basic position.

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 position 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 foot rest. Its basic
position can be adjusted to your seat position (see maintenance work).

Handlebar lock

The handlebar can be locked by means of the lock located on the control
head. Fully turn handlebar to right to lock, insert key, turn to left, press in,
turn to right and withdraw.

!

CAUTION

!

N

EVER LEAVE THE KEY INSERTED IN THE LOCK. IF YOU TURN THE STEERING TO THE LEFT

THE KEY COULD GET DAMAGED

.

2,3,4,5

1

N

1

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13

Compression damping of fork

The compression damping is to be set at the lower end of the fork tubes. It
only regulates the degree of damping during compression. Remove closing
cap

A. By using the knob 1 (COM), the degree of damping of the

compression can be adjusted. Turn the knob clockwise to increase damping,
turn it 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 1418X738 ..................... 20 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the knob

2, 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 1418X738 ..................... 15 clicks

Compression damping of shock absorber

With the knob 3 the degree of damping of the compression can be
adjusted. Turn the knob counterclockwise to increase damping, turn it
clockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT:

WP 0118X730 ................... position 4

Rebound damping of shock absorber

With the setting wheel 4 the degree of damping of the rebound can be
adjusted. Turn the knob to the left side to increase damping, turn it to the
right side to reduce damping during rebounding.

STANDARD ADJUSTMENT:

WP 0118X730 ................... position 8

A

1

2

2

3

4

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14

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read these operating instructions carefully before your first

ride.
– Enter the chassis, engine and key numbers on page 1.
– Familiarize yourself with the operating elements.
– Adjust the hand brake lever and foot brake lever to your

most comfortable position.
– Get used to handling the motorcycle on an empty parking

lot or open space, 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.
– Do not drive along off-road tracks which go beyond your

abitily and experience.
– Hold the handlebars with both hands and leave your feet on

the foot rests while driving.
– Remove your foot from the foot brake lever when you are

not braking. If the foot brake lever is not released the brake

pads rub continuously and the braking system is

overheated.
– 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.
– 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;

distribute 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 with protective clothing and helmet.
– Pay attention to running-in procedure.

Running in the LC4 models

Even very precisely machined sections of engine components
have rougher surfaces than components which have been
sliding against one another for quite some time. Therefore,
every engine needs to be broken in. For this reason, during its
first 1000 kilometers (620 miles) the engine must not be
revved up to its performance limits. The engine speed of 4800
r.p.m. must not be exceeded during the first 1000 kilometers
(620 miles). During this break-in time, you should ride your
motorcycle in different conditions (roads, easy off-road
terrain). The following table shows you the maximum velocity
values in the different gears at 4800 r.p.m. as based on the
rear wheel transmission ratio of your motorcycle.

NOTE:
D

URING THE STAGE OF RUNNING THE ENGINE IN, THAT IS THE FIRST

1000 KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF A

MINERAL OIL FORMULA

. THIS ALSO APPLIES IF THE ENGINE HAS BEEN

REPAIRED

.



WARNING



–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

COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS
POSSIBLE

. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE

CLOTHING

.

–D

ONOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE

.

–O

NLY 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 VEHICLES DRIVING
PROPERTIES

.

–T

HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY

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

.

–C

HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

–D

RIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.

–

RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR
GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY
SITUATION

. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

GOGGLES

, THE OPERATOR WILL BE BLINDED.

–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

.

–T

HESE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY -

NO ADDITIONAL PASSENGER ALLOWED!

–W

HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT

OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE

.

660 SMC

16:38 Z

1. G 35 kmh

2. G 55 kmh

3. G 80 kmh

4. G 95 kmh

5. G 110 kmh

gear

ratio

ENGLISH

15

Check the following before each start

When you start, the motorcycle must be in perfect mechanical 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 OIL LEVEL

Insufficient oil results in premature wear and consequently to engine
damage.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap,
check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain
can tear, and insufficient lubrication can result in unnecessary wear of
chain and chain wheels.

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 deteriorate the
driving performance.

5 BRAKES

Check correct functioning of the braking system. Check for sufficient
brake fluid in the reservoir. The reservoirs have been designed in such a
way that brake fluid does not need to be refilled even when the brake
pads are worn. If the level of brake fluid falls below the minimum 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,
as complete failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at hand brake lever and foot brake lever.

6 CABLES

Check correct setting and smooth operation of all control cables.

7 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

8 ELECTRICAL SYSTEM

Check correct operation of headlamps, tail-lights, brake lights, indicators,
control lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

DRIVING INSTRUCTIONS

ENGLISH

16

Starting when the engine is cold

1 Open the fuel tap 1
2 Swing up the side stand
3 Put the gear in neutral
4 Operate the choke

2

5 Go to the left of your motorbike. DO NOT open the throttle, and briskly

kick the kickstarter ALL THE WAY.



WARNING



–I

F 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 PUSH YOUR FOOT UPWARD WITH

GREAT VEHEMENCE

.

–A

LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.

K

ICKING THE KICKSTARTER WITH LESS ENOUGH FORCE AND AN OPENED THROTTLE

INCREASE THE KICK

-BACK HAZARD.

–D

O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH

.

A

LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

!

CAUTION

!

–B

EFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE SIDE STAND.

–D

ON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS

COLD

. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED

CYLINDER

, IT CAN CAUSE ENGINE DAMAGE.

NOTE:
This motorcycle is equipped with a safety starter 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 or hot

1 Open the fuel tap 1
2 Swing up the side stand
3 Put the gear in neutral
4 Push the hot start button

3

5 Go to the left of your motorbike. DO NOT open the throttle, and briskly

kick the kickstarter ALL THE WAY.

What to do when the engine is „flooded”

The throttle must be fully opened when starting. If necessary change
sparkplug.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch
lever and open throttle at the same time.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear. Depending
on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close
throttle, at the same time pull clutch lever in 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 opening the throttle all the way, turn
throttle back to

3

/

4; the speed will not decreases but the engine will use less

fuel.
Only give as much throttle as the engine can handle. Through quick and
high reving of throttle, the fuel consumption increases. When 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.

1

2

3