KTM 690 SMC 2011 Owners manual

4.5 (4)

OWNER'S MANUAL 2011

690 SMC EU

690 SMC AUS/UK

Art. no. 3211659en

DEAR KTM 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 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 misprints 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, as well as copying of all kinds, 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

MEANS OF REPRESENTATION ...............................................	6
IMPORTANT INFORMATION ...................................................	7
VIEW OF VEHICLE................................................................	12
View of vehicle, front left...................................................	12
View of vehicle, rear right ..................................................	14
SERIAL NUMBERS...............................................................	16
Chassis number................................................................	16
Type label........................................................................	16
Engine number.................................................................	17
Key number .....................................................................	17
Fork part number..............................................................	18
Shock absorber part number..............................................	18
CONTROLS ..........................................................................	19
Clutch lever .....................................................................	19
Hand brake lever ..............................................................	19
Throttle grip.....................................................................	20
Light switch .....................................................................	20
Turn signal switch ............................................................	21
Horn button .....................................................................	21
Emergency OFF switch......................................................	22
Electric starter button .......................................................	22
Ignition/steering lock ........................................................	23
Combination instrument....................................................	23
Combination instrument - function buttons .........................	24
Combination instrument - tachometer.................................	24
Combination instrument - indicator lamps...........................	25
Combination instrument - display.......................................	26
Combination instrument - speedometer...............................	27
Setting kilometers or miles ................................................	27

Combination instrument - time ..........................................	28
Setting the clock ..............................................................	28
Combination instrument - display ODO ...............................	29
Combination instrument - setting/resetting TRIP 1...............	29
Combination instrument - setting/resetting TRIP 2...............	30
Combination instrument - TRIP F display............................	31
Combination instrument - coolant temperature indicator ......	31
Opening the filler cap .......................................................	32
Closing filler cap ..............................................................	33
Seat release .....................................................................	33
Handrails.........................................................................	34
Passenger footrests...........................................................	34
Shift lever........................................................................	35
Foot brake lever................................................................	36
Side stand .......................................................................	36
PREPARING FOR USE..........................................................	37
Advice on first use............................................................	37
Running in the engine.......................................................	38
Loading the vehicle ..........................................................	39
RIDING INSTRUCTIONS .......................................................	41
Performing checks and vehicle care when preparing for
use .................................................................................	41
Starting ...........................................................................	42
Starting off ......................................................................	43
Shifting, riding.................................................................	43
Braking ...........................................................................	47
Stopping, parking .............................................................	48
Refueling.........................................................................	49

TABLE OF CONTENTS

SERVICE PLAN ....................................................................	52
Service schedule ..............................................................	52
TUNING THE CHASSIS.........................................................	55
Fork/shock absorber..........................................................	55
Adjusting the compression damping of the fork ...................	55
Adjusting the rebound damping of the fork..........................	56
Compression damping of the shock absorber .......................	57
Adjusting the low-speed compression damping of the shock
absorber ..........................................................................	57
Adjusting the high-speed compression damping of the
shock absorber .................................................................	58
Adjusting the rebound damping of the shock absorber..........	59
SERVICE WORK ON THE CHASSIS........................................	61
Raising the motorcycle with the front wheel stand ...............	61
Taking the motorcycle off of the front wheel stand ...............	61
Raising the motorcycle with the rear wheel stand.................	62
Taking the motorcycle off of the rear wheel stand ................	62
Bleeding the fork legs .......................................................	63
Removing the seat ............................................................	63
Mounting the seat ............................................................	64
Removing the air filter x.................................................	64
Installing the air filter x..................................................	65
Checking the chain for dirt ................................................	66
Cleaning the chain............................................................	66
Checking the chain tension ...............................................	68
Adjusting the chain tension ...............................................	69
Check the chain, rear sprocket, engine sprocket and chain
guide...............................................................................	71
Adjusting basic position of clutch lever...............................	75

Checking/rectifying the fluid level of the hydraulic clutch	..... 76
BRAKES ..............................................................................	77
Adjusting the basic position of the hand brake lever.............	77
Checking the brake discs...................................................	77
Checking the front brake fluid level ....................................	78
Adding front brake fluid x...............................................	79
Checking the front brake linings.........................................	80
Checking the free travel of foot brake lever..........................	81
Adjusting the basic position of the foot brake lever x.........	82
Checking rear brake fluid level...........................................	83
Adding rear brake fluid x................................................	83
Checking the rear brake linings ..........................................	85
WHEELS, TIRES ..................................................................	87
Removing front wheel x..................................................	87
Installing the front wheel x..............................................	88
Removing rear wheel x....................................................	90
Installing the rear wheel x...............................................	91
Checking the rear hub rubber dampers x..........................	93
Checking the tire condition................................................	94
Checking the tire air pressure ............................................	95
Checking the spoke tension ...............................................	96
ELECTRICAL SYSTEM ..........................................................	98
Removing the battery x...................................................	98
Installing the battery x....................................................	99
Recharging the battery x.................................................	99
Changing the main fuse ..................................................	101
Changing fuses of individual power consumers ..................	103
Removing the headlight mask with the headlight ...............	105

TABLE OF CONTENTS

Installing the headlight mask with the headlight................	106
Changing the headlight bulb............................................	107
Changing the parking light bulb .......................................	108
Changing the turn signal bulb ..........................................	109
Checking the low beam headlight adjustment....................	110
Adjusting the headlight range ..........................................	111
COOLING SYSTEM .............................................................	112
Cooling system ...............................................................	112
Checking the antifreeze and coolant level .........................	112
Checking the coolant level...............................................	114
Draining the coolant x..................................................	116
Filling the cooling system x...........................................	117
TUNING THE ENGINE ........................................................	119
Checking the play in the throttle cable..............................	119
Adjusting the play in the throttle cable x........................	120
Adjusting the engine characteristic...................................	120
SERVICE WORK ON THE ENGINE .......................................	122
Checking the engine oil level ...........................................	122
Changing the engine oil and filter, cleaning the oil
screens x.....................................................................	123
Draining the engine oil x...............................................	123
Removing the oil filter x................................................	124
Cleaning the oil screens x.............................................	126
Installing the oil filter x................................................	128
Filling up with engine oil x............................................	128
Adding engine oil ...........................................................	129
CLEANING, CARE ..............................................................	131
Cleaning the motorcycle ..................................................	131
Protective treatment for winter operation ..........................	133

STORAGE ..........................................................................	134
Storage..........................................................................	134
Preparing for use after storage .........................................	135
TROUBLESHOOTING..........................................................	136
BLINK CODE .....................................................................	139
TECHNICAL DATA - ENGINE...............................................	144
Capacity - engine oil .......................................................	145
Capacity - coolant...........................................................	145
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	146
TECHNICAL DATA - CHASSIS .............................................	149
Lighting equipment ........................................................	150
Tires .............................................................................	151
Capacity - fuel................................................................	151
TECHNICAL DATA - FORK...................................................	152
TECHNICAL DATA - SHOCK ABSORBER ..............................	153
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........	155
SUBSTANCES....................................................................	158
AUXILIARY SUBSTANCES...................................................	162
STANDARDS......................................................................	164
INDEX ...............................................................................	165

MEANS OF REPRESENTATION

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 performed in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

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

Formats used

The following typographical formats are used.

Specific name	Identifies a proprietary name.
Name®	Identifies a protected name.
Brand™	Identifies a brand in merchandise traffic.

IMPORTANT INFORMATION

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.

Service

A prerequisite for fault-free operation and avoiding premature wear is compliance with the instructions for maintenance, care and tuning of the engine and suspension provided in the owner's manual. 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.

It is imperative that you adhere to the stipulated run-in times and service 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

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.

Ensure that the vehicle is roadworthy after completing repair and maintenance work.

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

–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

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.

	VIEW OF VEHICLE	12

	View3.1 of vehicle, front left

600637-10

VIEW OF VEHICLE

1Hand brake lever ( p. 19)

2Clutch lever ( p. 19)

3Seat

4Filler cap

5Handrails ( p. 34)

6Engine number ( p. 17)

7Shift lever ( p. 35)

8Side stand ( p. 36)

9Footrest

10Seat release ( p. 33)

	VIEW OF VEHICLE	14

	View3.2 of vehicle, rear right

600638-10

VIEW OF VEHICLE

1Ignition/steering lock ( p. 23)

2Light switch ( p. 20)

2	Turn signal switch ( p. 21)

2Horn button ( p. 21)

3Rear mirror

4Combination instrument ( p. 23)

5Emergency OFF switch ( p. 22)

5Electric starter button ( p. 22)

6Throttle grip ( p. 20)

7Chassis number ( p. 16)

8Passenger footrests ( p. 34)

9Shock absorber, rebound adjustment

10Foot brake lever ( p. 36)

11Level viewer, engine oil

SERIAL NUMBERS

Chassis4.1 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

SERIAL NUMBERS		17

Engine4.3	number
		The engine number is stamped on the left side of the engine under the engine sprocket.

600479-10

Key4.4 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

SERIAL NUMBERS

Fork4.5 part number

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

600480-10

Shock4.6 absorber part number

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

100216-10

CONTROLS

Clutch5.1 lever

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

The clutch is hydraulically operated and self-adjusting.

700542-01

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.

600598-11

CONTROLS

Throttle5.3 grip

The throttle grip is fitted on the right side of the handlebar.

101069-10

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

CONTROLS

Turn5.5 signal switch

100223-10

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.

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

Horn5.6 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

CONTROLS

Emergency5.7 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

Electric5.8 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

CONTROLS

Ignition/steering5.9 lock

600825-01

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.

Combination5.10 instrument

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

Function buttonsTachometer

Indicator lightsDisplay

400832-10

CONTROLS

Combination5.11 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 master 2 (TRIP 2).

Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0.

Button has no function.

400833-10

Combination5.12 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

CONTROLS

Combination5.13 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
	400835-01	on.
		on.

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

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

FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagnosis) has identified an emissionsor safety-critical fault.

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

CONTROLS

Combination5.14 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.

The display then changes to the last selected mode.

400881-01

CONTROLS		27

Combination5.15	instrument - speedometer
		The speed is shown in kilometers per hour km/h or in miles per hour mph.

400838-10

Setting5.16 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		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 pressed until the display mode changes from km/h to mph or
		from mph to km/h.

400839-01

Combination5.17 instrument - time

The time is shown in area of the display.

Info

After reconnecting the battery or changing the fuse, the time must be reset.

400838-11

Setting5.18 the clock

Condition

The motorcycle is stationary.

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