KTM 690 SMC 2010 Owners manual

OWNER'S MANUAL 2010

690 SMC EU

690 SMC AUS/UK

Art. no. 3211517en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to buy 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 a lot of enjoyment in riding this 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. Slight deviations resulting from continuing devel­opment and design of our vehicles cannot, however, be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically 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 misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
According to 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

TABLE OF CONTENTS 3

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................... 6

IMPORTANT INFORMATION ................................................... 7

VIEW OF VEHICLE................................................................ 12

View of vehicle, front left side............................................ 12

View of vehicle, rear right .................................................. 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

CONTROLS.......................................................................... 19

Clutch lever ..................................................................... 19

Hand brake lever .............................................................. 19

Light switch..................................................................... 20

Turn signal switch ............................................................ 20

Horn button ..................................................................... 21

Emergency OFF switch...................................................... 21

Electric starter button ....................................................... 22

Ignition/steering lock ........................................................ 22

Combination instrument.................................................... 23

Combination instrument - function buttons......................... 23

Combination instrument - tachometer................................. 24

Combination instrument - indicator lamps........................... 24

Combination instrument - display....................................... 25

Combination instrument - speedometer............................... 26

Setting kilometers or miles ................................................ 26

Combination instrument - time .......................................... 27

Setting the clock .............................................................. 27

Combination instrument - display ODO ............................... 28

Combination instrument - setting/resetting TRIP 1............... 28

Combination instrument - setting/resetting TRIP 2............... 29

Combination instrument - TRIP F display............................ 30

Combination instrument - coolant temperature indicator ...... 30

Opening filler cap............................................................. 31

Closing filler cap .............................................................. 31

Handrails......................................................................... 32

Seat release..................................................................... 32

Passenger footrests........................................................... 33

Shift lever........................................................................ 33

Foot brake lever................................................................ 34

Side stand ....................................................................... 35

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION......................................................................... 36

Advice on first use............................................................ 36

Running in the engine....................................................... 37

Loading the vehicle .......................................................... 38

RIDING INSTRUCTIONS....................................................... 40

Checks before putting into operation .................................. 40

Starting ........................................................................... 41

Starting up ...................................................................... 42

Shifting, riding................................................................. 42

Braking ........................................................................... 46

Stopping, parking............................................................. 47

Refueling......................................................................... 48

SERVICE SCHEDULE............................................................ 51

Service schedule .............................................................. 51

TABLE OF CONTENTS 4

MAINTENANCE WORK ON CHASSIS AND ENGINE................. 54

Jacking up front of motorcycle........................................... 54

Taking the front from the work stand.................................. 54

Jacking up rear of motorcycle ............................................ 55

Taking the rear from the work stand ................................... 55

Fork/shock absorber.......................................................... 56

Adjusting the compression damping of the fork ................... 56

Adjusting rebound damping of fork..................................... 57

Compression damping of the shock absorber ....................... 58

Adjusting the low-speed compression damping of the shock

absorber .......................................................................... 58

Adjusting the high-speed compression damping of the

shock absorber................................................................. 59

Adjusting the rebound damping of the shock absorber.......... 60

Measuring the unloaded rear wheel sag............................... 61

Checking the static sag of the shock absorber ..................... 62

Checking the riding sag of the shock absorber..................... 63

Adjusting the spring preload of the shock absorber x ......... 63

Bleeding the fork legs ....................................................... 64

Cleaning the dust boots of the fork legs .............................. 65

Removing the fork protector............................................... 66

Installing the fork protector ............................................... 67

Checking the steering head bearing play ............................. 67

Adjusting play of steering head bearing x.......................... 68

Handlebar position ........................................................... 69

Adjusting handlebar position x ........................................ 70

Checking the chain for dirt ................................................ 71

Cleaning the chain............................................................ 71

Checking the chain tension ............................................... 72

Adjusting the chain tension ............................................... 73

Checking the chain, rear sprocket and engine sprocket......... 75

Adjusting chain guide x.................................................. 78

Checking the brake discs................................................... 78

Adjusting the basic position of the hand brake lever............. 79

Checking the front brake fluid level .................................... 80

Adding front brake fluid x............................................... 80

Checking the front brake linings......................................... 82

Changing the front brake linings x ................................... 83

Removing front brake linings x........................................ 85

Installing the front brake linings x ................................... 86

Checking the free travel of foot brake lever.......................... 88

Adjusting the basic position of the foot brake lever x......... 89

Checking rear brake fluid level........................................... 90

Adding rear brake fluid x ................................................ 90

Checking the rear brake linings.......................................... 92

Changing rear brake linings x.......................................... 93

Removing front wheel x .................................................. 96

Installing the front wheel x.............................................. 97

Removing rear wheel x.................................................... 99

Installing the rear wheel x............................................. 100

Checking the rear hub rubber dampers x........................ 102

Checking the tire condition.............................................. 103

Checking the spoke tension ............................................. 104

Tubeless tire system ....................................................... 106

Checking the tire air pressure .......................................... 106

Removing the seat .......................................................... 107

Mounting the seat .......................................................... 108

TABLE OF CONTENTS 5

Removing the battery x................................................. 108

Installing the battery x.................................................. 109

Recharging the battery x............................................... 110

Changing the main fuse .................................................. 112

Changing the fuses of individual power consumers............. 114

Adjusting the engine characteristic................................... 116

Removing the headlight mask with the headlight ............... 117

Installing the headlight mask with the headlight................ 119

Changing the headlight bulb............................................ 120

Changing the parking light bulb ....................................... 121

Changing the flasher bulb ............................................... 122

Checking the headlight setting......................................... 123

Adjusting the headlight range .......................................... 124

Removing the air filter x ............................................... 124

Installing the air filter x................................................ 126

Cooling system............................................................... 127

Checking the antifreeze and coolant level ......................... 127

Checking the coolant level............................................... 129

Draining the coolant x .................................................. 131

Filling the cooling system x........................................... 132

Adjusting basic position of clutch lever............................. 133

Checking/rectifying the fluid level of the hydraulic clutch ... 134

Checking the play in the throttle cable.............................. 135

Adjusting the play in the throttle cable x........................ 136

Checking the engine oil level ........................................... 136

Changing the engine oil and filter, cleaning the oil

screens x..................................................................... 137

Draining the engine oil x............................................... 137

Removing the oil filter x................................................ 138

Installing the oil filter x................................................ 140

Cleaning the oil screens x............................................. 140

Filling up with engine oil x............................................ 142

Adding engine oil ........................................................... 143

TROUBLESHOOTING.......................................................... 145

BLINK CODE ..................................................................... 148

CLEANING......................................................................... 153

Cleaning the motorcycle .................................................. 153

PROTECTIVE TREATMENT FOR WINTER OPERATION........... 155

Protective treatment for winter operation .......................... 155

STORAGE .......................................................................... 156

Storage.......................................................................... 156

Putting into operation after storage .................................. 157

TECHNICAL DATA - ENGINE............................................... 158

Capacity - engine oil ....................................................... 159

Capacity - coolant........................................................... 159

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 160

TECHNICAL DATA - CHASSIS ............................................. 163

Lighting equipment ........................................................ 164

Tires ............................................................................. 165

Capacity - fuel................................................................ 165

TECHNICAL DATA - FORK................................................... 166

TECHNICAL DATA - SHOCK ABSORBER .............................. 167

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 169

SUBSTANCES.................................................................... 172

AUXILIARY SUBSTANCES................................................... 176

STANDARDS...................................................................... 179

INDEX ............................................................................... 180

MEANS OF REPRESENTATION 6

Symbols used

The meaning of specific symbols is described below.

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 below.

Specific name Identifies a proprietary name.

®

Name

Brand™ Identifies a trademark.

Identifies a protected name.

IMPORTANT INFORMATION 7

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.

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 ser­vice schedule 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 work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth­erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes
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 INFORMATION 8

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe­ses. Example: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

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

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being

run. Always let the vehicle cool first.

IMPORTANT INFORMATION 9

– 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.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize potential hazards and may therefore be injured.

IMPORTANT INFORMATION 10

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful 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.

– 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.

11

VIEW OF VEHICLE 12

3.1View of vehicle, front left side

600637-10

VIEW OF VEHICLE 13

1 Hand brake lever
2 Clutch lever
3 Seat
4 Filler cap
5 Handrail
6 Front brake caliper
7 Shift lever
8 Engine number
9 Side stand
10 Footrest
11 Seat release strap

VIEW OF VEHICLE 14

3.2View of vehicle, rear right

600638-10

VIEW OF VEHICLE 15

1 Ignition/steering lock
2 Light switch, flasher switch, horn button
3 Rear mirror
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Throttle grip
7 Chassis number
8 Brake caliper, rear
9 Passenger footrest
10 Shock absorber, rebound damping
11 Foot brake pedal
12 Level viewer, engine oil

LOCATION OF SERIAL NUMBERS 16

4.1Chassis number

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

100217-10

4.2Type label

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

100218-10

LOCATION OF SERIAL NUMBERS 17

4.3Key number

The key number  can be found on the KEYCODECARD.

Info

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

100179-10

4.4Engine number

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

600479-10

LOCATION OF SERIAL NUMBERS 18

4.5Fork part number

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

600480-10

4.6Shock absorber part number

The shock absorber part number  is on the right of the shock absorber.

100216-10

CONTROLS 19

5.1Clutch lever

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

700542-01

5.2Hand brake lever

The hand break lever  is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.

600598-11

CONTROLS 20

5.3Light 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

5.4Turn signal switch

The turn signal switch  is fitted on the left side of the handlebar.

Possible states

Turn signal off
Turn signal light, left, on – Turn signal switch pressed to the left. The turn

signal switch returns automatically to the central position after use.

Turn signal light, right, on – Turn signal switch pressed to the right. The
turn signal switch returns automatically to the central position after use.

100223-10

To switch off the turn signal light, press the turn signal switch towards the switch case.

CONTROLS 21

5.5Horn button

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

5.6Emergency OFF switch

The emergency OFF switch  is fitted on the right 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

CONTROLS 22

5.7Electric 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

5.8Ignition/steering 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

600825-01

steering locked. The ignition key can be removed.

CONTROLS 23

5.9Combination instrument

The combination instrument is installed in front of the handlebar.
The combination instrument is divided into 4 function areas.

 Function buttons
 Tachometer
 Indicator lights
 Display

400832-10

5.10Combination instrument - function buttons

You can change the display mode with the MODE button .
Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas-
ter 2 (TRIP 2).
Press the SET button  to reset the trip master 1 function (TRIP 1) and trip master 2 func-
tion (TRIP 2) to 0.0.
Button  has no function.

400833-10

CONTROLS 24

5.11Combination instrument - tachometer

The tachometer  shows the engine speed in revolutions per minute.
The red marking  shows the excess speed range of the engine.

400834-10

5.12Combination instrument - indicator lamps

The indicator lamps offer additional information about the operating state of the motorcy­cle.

Possible states

The turn signal indicator lamp flashes green simultaneously with the turn
signal – The turn signal is switched on.

The idle speed indicator lamp lights up green – The transmission is shifted
to idle.

400835-01

The high beam indicator lamp lights up blue – The 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 switched to TRIP F.

CONTROLS 25

FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an

emission- or safety-critical fault.

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

5.13Combination instrument - display

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

400836-01

LEnGth

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

Info

1870 mm corresponds to the circumference of the 17" front wheel with a series pro­duction tire.

400881-01

The display then changes to the last selected mode.

CONTROLS 26

5.14Combination instrument - speedometer

The speed  is shown in kilometers per hour km/h or in miles per hour mph.

400838-10

5.15Setting kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.

Condition

The motorcycle is stationary.

CONTROLS 27

– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from km/h to mph or

from mph to km/h.

400839-01

5.16Combination instrument - time

The time is shown in area  of the display.

Info

The time has to be reset after the battery is reconnected or when the fuse is
changed.

400838-11

5.17Setting the clock

Condition

The motorcycle is stationary.

CONTROLS 28

– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button and the SET button pressed simultaneously.

The time display begins to flash.

– Press the MODE button to set the hour.
– Press the SET button to set the minute.
– Keep the MODE button and the SET button pressed simultaneously.

400838-01

5.18Combination instrument - display ODO

In the ODO display mode, the total distance traveled is shown in kilometers or miles.

400839-01

The time is set.

Info

This value is retained, even if the battery is disconnected and/or the fuse blows.

5.19Combination instrument - setting/resetting TRIP 1

Info

The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.