KTM 690 SMC Manual

5 (1)

OWNER'S MANUAL 2008

690 ENDURO EU

690 ENDURO AUS/UK

ART. NO. 3211239en

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( P. 16)

Dealer's stamp

Engine number ( P. 17)

Key number ( P. 17)

The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small deviations arising from further development in design and construction.

All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

CONTENTS

MEANS OF REPRESENTATION ...............................................	7
IMPORTANT NOTES...............................................................	8
VIEW OF VEHICLE................................................................	12
View of vehicle, front left side............................................	12
View of vehicle, rear right side ...........................................	14
LOCATION OF SERIAL NUMBERS .........................................	16
Chassis number................................................................	16
Type label........................................................................	16
Key number .....................................................................	17
Engine number.................................................................	17
Fork part number..............................................................	18
Shock absorber part number..............................................	18
OPERATING ELEMENTS.......................................................	19
Clutch lever .....................................................................	19
Hand brake lever ..............................................................	19
Light switch .....................................................................	20
Light switch .....................................................................	20
Headlight flasher switch....................................................	21
Flasher switch..................................................................	21
Flasher switch..................................................................	22
Horn ...............................................................................	22
Horn ...............................................................................	23
Emergency OFF switch......................................................	23
Electric starter button .......................................................	24
Ignition/steering lock ........................................................	24
Combination instrument....................................................	25
Combination instrument - function buttons .........................	25
Combination instrument - tachometer.................................	26
Combination instrument - control lamps .............................	26

Combination instrument - Display ......................................	27
Combination instrument - speed display .............................	28
Setting kilometers or miles ................................................	28
Combination instrument - time ..........................................	29
Setting the clock ..............................................................	29
Combination instrument - ODO display ...............................	30
Combination instrument - setting/resetting TRIP 1 display....	30
Combination instrument - setting/resetting TRIP 2 display....	31
Combination instrument - TRIP F display ............................	32
Combination instrument - coolant temperature indicator ......	32
Opening filler cap.............................................................	33
Closing filler cap ..............................................................	33
Handrails.........................................................................	34
Seat release .....................................................................	34
Passenger footrests...........................................................	35
Shift lever........................................................................	35
Foot brake pedal ..............................................................	36
Side stand .......................................................................	37
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION.........................................................................	38
Advice on first use............................................................	38
Running in the engine.......................................................	40
Loading the vehicle ..........................................................	40
RIDING INSTRUCTIONS .......................................................	42
Checks before putting into operation ..................................	42
Starting ...........................................................................	43
Starting up ......................................................................	45
Shifting, riding.................................................................	45
Braking ...........................................................................	48

CONTENTS

Stopping, parking .............................................................	49
Refueling.........................................................................	51
GREASING AND SERVICE TABLE ..........................................	53
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................	53
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)...................	55
MAINTENANCE WORK ON CHASSIS AND ENGINE.................	56
Jacking up the motorcycle .................................................	56
Removing the motorcycle from the work stand.....................	56
Fork/shock absorber..........................................................	57
Adjusting compression damping of fork ..............................	57
Adjusting rebound damping of fork.....................................	58
Compression damping of shock absorber.............................	59
Adjusting the low-speed compression damping of the shock
absorber ..........................................................................	59
Adjusting high-speed compression damping of the shock
absorber ..........................................................................	60
Adjusting rebound damping of the shock absorber ...............	62
Bleeding fork legs.............................................................	62
Cleaning dust boots of fork legs .........................................	63
Loosening the fork protection.............................................	64
Positioning the fork protection ...........................................	64
Checking play of steering head bearing x..........................	65
Adjusting play of steering head bearing x..........................	66
Adjusting the handlebar angle x.......................................	67
Handlebar position ...........................................................	67
Adjusting handlebar position x........................................	68
Checking chain dirt ..........................................................	69

Cleaning the chain............................................................	69
Checking the chain tension ...............................................	70
Adjusting chain tension.....................................................	71
Checking rear sprocket / engine sprocket for wear ................	73
Checking chain wear.........................................................	74
Adjusting chain guide x..................................................	75
Checking brake discs ........................................................	75
Checking free play of hand brake lever................................	76
Adjusting free travel of handbrake lever ..............................	77
Checking front brake fluid level..........................................	78
Adding brake fluid for front brake x..................................	78
Brake linings....................................................................	80
Checking the front brake linings.........................................	81
Changing the front brake linings x....................................	81
Checking free play of foot brake lever .................................	85
Adjusting basic position of foot brake pedal x...................	85
Checking rear brake fluid level...........................................	86
Topping up brake fluid of rear brake x..............................	87
Checking the rear brake linings ..........................................	89
Changing rear brake linings x..........................................	89
Removing front wheel x..................................................	92
Fitting front wheel x.......................................................	94
Removing rear wheel x....................................................	95
Fitting rear wheel x........................................................	96
Checking the rear hub rubber dampers x..........................	97
Tire condition checking.....................................................	98
Checking tire air pressure................................................	100
Checking spoke tension...................................................	101

CONTENTS

Removing the seat ..........................................................	102
Mounting the seat ..........................................................	103
Removing the battery x.................................................	103
Installing the battery x..................................................	104
Recharging the battery x...............................................	105
Changing the main fuse ..................................................	107
Changing fuses of individual power consumers ..................	109
Adjusting the engine characteristic...................................	111
Removing headlight mask with headlight ..........................	113
Refitting the headlight mask with the headlight.................	114
Changing the headlight bulb............................................	115
Changing the parking light bulb .......................................	116
Changing the flasher bulb ...............................................	117
Checking headlamp setting..............................................	118
Adjusting the headlight range ..........................................	119
Removing the air filter x...............................................	119
Installing the air filter x................................................	120
Cooling system ...............................................................	121
Checking the antifreeze and coolant level .........................	122
Checking the coolant level...............................................	124
Draining coolant x........................................................	126
Filling the cooling system x...........................................	127
Adjusting basic position of clutch lever.............................	129
Checking/correcting fluid level of hydraulic clutch .............	129
Checking play in gas Bowden cable ..................................	130
Adjusting play in gas Bowden cable x.............................	131
Removing the engine guard .............................................	132
Installing the engine guard ..............................................	132
Checking engine oil level.................................................	133

Changing engine oil and oil filter, cleaning oil
screens x.....................................................................	133
Draining engine oil x....................................................	134
Removing the oil filter x................................................	135
Mounting oil filter x......................................................	137
Cleaning oil screens x...................................................	137
Filling up with engine oil x............................................	139
Topping up engine oil .....................................................	140
TROUBLESHOOTING..........................................................	141
FLASHING CODE ...............................................................	144
CLEANING.........................................................................	147
Cleaning motorcycle .......................................................	147
CONSERVATION FOR WINTER OPERATION .........................	149
Conservation for winter operation .....................................	149
STORAGE ..........................................................................	150
Storage..........................................................................	150
Putting into operation after storage ..................................	151
TECHNICAL DATA - ENGINE...............................................	152
Capacity - engine oil .......................................................	153
Capacity - coolant...........................................................	153
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	154
TECHNICAL DATA - CHASSIS .............................................	157
Lighting equipment ........................................................	158
Capacity - fuel................................................................	159
TECHNICAL DATA - FORK...................................................	160
TECHNICAL DATA - SHOCK ABSORBER ..............................	161
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........	163
SUBSTANCES....................................................................	166
AUXILIARY SUBSTANCES...................................................	169

CONTENTS	6
STANDARDS......................................................................	171
INDEX ...............................................................................	172

MEANS OF REPRESENTATION

Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Eigenname	Indicates a proprietary name.
Name®	Identifies a protected name.
Marke™	Identifies a brand in merchandise traffic.

IMPORTANT NOTES

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES

Spare parts, accessories

For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Transport

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

–Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

–Do not place the vehicle where there are flammable or explosive substances.

–Switch off the engine and remove the ignition key.

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

IMPORTANT NOTES

Notes/warning notes

Pay attention to the specified notes and warnings.

Info

Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Caution

Danger that could possibly lead to slight injuries.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

–Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

IMPORTANT NOTES

–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

	VIEW OF VEHICLE	12

	3View.1 of vehicle, front left side

100234-10

VIEW OF VEHICLE

1Hand brake lever

2Clutch lever

3Handrail

4Filler cap

5Seat

6Front brake caliper

7Shift lever

8Engine number

9Side stand

10Footrest

11Seat release strap

	VIEW OF VEHICLE	14

	View3.2 of vehicle, rear right side

100235-10

VIEW OF VEHICLE

1Ignition/steering lock

2Rear mirror

3Light switch, flasher switch, horn

4Combination instrument

5Emergency OFF switch, electric starter button

6Throttle grip

7Chassis number

8Rear brake caliper

9Passenger footrest

10Shock absorber rebound damping

11Foot brake pedal

12Engine oil level viewer

LOCATION OF SERIAL NUMBERS

4Chassis.1 number

The chassis number is stamped on the steering head on the right.

100217-10

Type4.2 label

Type label is located on the upper right frame tube below the seat.

100218-10

LOCATION OF SERIAL NUMBERS			17

Key4.3 number
	The key number can be found on the KEYCODECARD.
	The key number can be found on the KEYCODECARD.

		Info
		Info
		You need the key number to order a spare key. Keep the KEYCODECARD in a safe
		place.

100179-10

Engine4.4 number

The engine number is stamped on the left side of the engine under the engine sprocket.

100211-10

LOCATION OF SERIAL NUMBERS

Fork4.5 part number

The fork part number is stamped on the inner side of the fork stub.

100214-10

Shock4.6 absorber part number

Shock absorber part number can be viewed from the right side.

100216-10

OPERATING ELEMENTS

5Clutch.1 lever

The clutch lever is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

100219-10

Hand5.2 brake lever

The hand break lever is fitted on the right side of the handlebar.

The hand brake lever operates the front brake.

100220-10

OPERATING ELEMENTS

Light5.3 switch

The light switch is fitted on the left side of the handlebar.

Possible states

Low beam on – Light switch is turned downwards. In this position, the low

beam and tail light are switched on.

High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

500020-01

Light5.4 switch

The light switch is fitted on the left side of the handlebar.

Possible states

Low beam on – Light switch is turned downwards. In this position, the low

beam and tail light are switched on.

High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

100222-10

OPERATING ELEMENTS

Headlight5.5 flasher switch

The headlight flasher switch is fitted on the left side of the handlebar.

Possible states

•Headlight flasher switch in neutral position

•Headlight flasher switch pressed – In this position, the headlight flasher (high beam) is actuated.

500020-11

Flasher5.6 switch

The flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off

Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

500021-10

OPERATING ELEMENTS

Flasher5.7 switch

The flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off

Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

100223-10

Horn5.8

The horn button is fitted on the left side of the handlebar.

Possible states

•Horn button in neutral position

•Horn button pressed – The horn is operated in this position.

500021-11

OPERATING ELEMENTS

Horn5.9

The horn button is fitted on the left side of the handlebar.

Possible states

•Horn button in neutral position

•Horn button pressed – The horn is operated in this position.

100224-10

Emergency5.10 OFF switch

The emergency OFF switch is fitted on the left side of the handlebar.

Possible states

Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.

Emergency OFF switch on – This position is necessary for operation as the ignition circuit is closed.

100225-10

OPERATING ELEMENTS

Electric5.11 starter button

The electric starter button is fitted on the right side of the handlebar.

Possible states

•Electric starter button in basic position

•Electric starter button pressed – In this position, the electric starter is actuated.

100226-10

Ignition/steering5.12 lock

The ignition/steering lock is located in front of the seat.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

Ignition on – In this position, the ignition circuit is closed, and the engine can be started.

Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed.

100221-10

OPERATING ELEMENTS

Combination5.13 instrument

The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas.

Function buttonsTachometer

Indicator lightsDisplay

700116-01

Combination5.14 instrument - function buttons

Press the MODE button to change the display mode.

Possible display modes are total distance covered (ODO), tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2).

Press the SET button to reset tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2) to 0.0. Button has no function.

700117-01

OPERATING ELEMENTS

Combination5.15 instrument - tachometer

The tachometer displays the engine speed in revolutions per minute.

The red marking shows the excess engine speed range.

100118-10

Combination5.16 instrument - control lamps

100119-10

The indicator lamps provide additional information on the operating state of the motorcycle.

Possible states

Flashing indicator flashes green in flash rhythm – Flasher light is switched on.

Idling speed indicator lamp lights up green – Transmission is in neutral.

High beam indicator lamp lights up blue – High beam is switched on.

Temperature warning lamp lights up red – Coolant has reached a critical value.

Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark. Display switches to TRIP F.

FI warning lamp (MIL) lights/flashes orange – The OBD has detected an emissionor safety-critical error.

OPERATING ELEMENTS

Combination5.17 instrument - Display

700118-01

400404-01

Battery warning lamp lights up – Voltage in electrical system too low.

When you switch on the ignition, all display segments light up for a second as a function test.

LEnGTth

Following the display function test, the wheel circumference LEnGth is shown for one second.

Info

2205 mm equals the circumference of the 21" front wheel with a series production tire.

The display then changes to the last selected mode.

OPERATING ELEMENTS		28

Combination5.18	instrument - speed display
		The speed is displayed in kilometers per hour km/h or miles per hour Mph.

700114-01

Setting5.19 kilometers or miles

Info

If you change the unit, the ODO value is retained and converted accordingly.

Making the setting according to the country.

Condition

The motorcycle is standing.

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