KTM 690 SMC UK, 690 SMC AUS, 690 SMC EU User Manual
OWNER'S MANUAL 2008
690bSMCbEU
690bSMCbAUS/UK
ART. NO. 3211245en
DEAR KTM CUSTOMER 1
'($5.70 &86720(5
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 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 may contain special equipment that
does not belong to the regular scope of delivery.
DEAR KTM CUSTOMER 2
© 2008 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)
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 3
&217(176
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 -bODO display ............................... 30
Combination instrument - setting/resettingbTRIPb1 display .... 30
Combination instrument - setting/resettingbTRIPb2 display .... 31
Combination instrument -bTRIPbF 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....................................................... 39
Loading the vehicle .......................................................... 40
RIDING INSTRUCTIONS ....................................................... 42
Checks before putting into operation .................................. 42
Starting ........................................................................... 43
Starting up ...................................................................... 45
Shifting, riding ................................................................. 45
Braking ........................................................................... 48
CONTENTS 4
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 front of motorcycle ........................................... 56
Taking front from work stand ............................................. 56
Jacking up rear of motorcycle ............................................ 57
Take the rear from the work stand. ..................................... 57
Fork/shock absorber .......................................................... 58
Adjusting compression damping of fork .............................. 58
Adjusting rebound damping of fork..................................... 59
Compression damping of shock absorber............................. 60
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 60
Adjusting high-speed compression damping of the shock
absorber .......................................................................... 61
Adjusting rebound damping of the shock absorber ............... 63
Bleeding fork legs............................................................. 63
Cleaning dust boots of fork legs ......................................... 64
Removing the fork protector............................................... 65
Installing the fork protector ............................................... 66
Checking play of steering head bearingb
Adjusting play of steering head bearingb
Handlebar position ........................................................... 68
Adjusting handlebar positionb
x ........................................ 69
x .......................... 66
x.......................... 67
Adjusting the handlebar angleb
Checking chain dirt .......................................................... 70
Cleaning the chain............................................................ 70
Checking the chain tension ............................................... 71
Adjusting chain tension..................................................... 72
Checking rear sprocket / engine sprocket for wear ................ 74
Checking chain wear ......................................................... 75
Adjusting chain guideb
Checking brake discs ........................................................ 76
Adjusting basic position of handbrake lever......................... 77
Checking front brake fluid level.......................................... 78
Adding brake fluid for front brakeb
Brake linings.................................................................... 80
Checking the front brake linings......................................... 81
Changing the front brake liningsb
Removing front brake liningsb
Mounting front brake liningsb
Checking free play of foot brake lever ................................. 86
Adjusting basic position of foot brake pedalb
Checking rear brake fluid level........................................... 87
Topping up brake fluid of rear brakeb
Checking the rear brake linings .......................................... 90
Changing rear brake liningsb
Removing front wheelb
Installing the front wheelb
Removing rear wheelb
Installing the rear wheelb
Checking the rear hub rubber dampersb
x .................................................. 76
x .................................................. 93
x.................................................... 96
x....................................... 70
x.................................. 78
x.................................... 81
x ........................................ 83
x ......................................... 84
x ................... 86
x.............................. 88
x .......................................... 90
x.............................................. 95
x ............................................... 97
x .......................... 99
CONTENTS 5
Tire condition checking ................................................... 100
Checking spoke tension................................................... 101
Checking tire air pressure................................................ 102
Removing the seat .......................................................... 103
Mounting the seat .......................................................... 103
Removing the batteryb
Installing the batteryb
Recharging the batteryb
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 filterb
Installing the air filterb
Cooling system ............................................................... 121
Checking the antifreeze and coolant level ......................... 122
Checking the coolant level............................................... 124
Draining coolantb
Filling the cooling systemb
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 cableb
x ................................................. 104
x.................................................. 105
x ............................................... 105
x ............................................... 119
x ................................................ 120
x ........................................................ 126
x ........................................... 127
x............................. 131
Checking engine oil level................................................. 132
Changing engine oil and oil filter, cleaning oil
screensb
Draining engine oilb
Removing the oil filterb
Mounting oil filterb
Cleaning oil screensb
Filling up with engine oilb
Topping up engine oil ..................................................... 139
TROUBLESHOOTING.......................................................... 140
FLASHING CODE ............................................................... 143
CLEANING......................................................................... 146
Cleaning motorcycle ....................................................... 146
CONSERVATION FOR WINTER OPERATION ......................... 148
Conservation for winter operation ..................................... 148
STORAGE .......................................................................... 149
Storage.......................................................................... 149
Putting into operation after storage .................................. 150
TECHNICAL DATA - ENGINE ............................................... 151
Capacity - engine oil ....................................................... 152
Capacity - coolant........................................................... 152
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........... 153
TECHNICAL DATA - CHASSIS ............................................. 156
Lighting equipment ........................................................ 157
Capacity - fuel................................................................ 158
TECHNICAL DATA - FORK................................................... 159
TECHNICAL DATA - SHOCK ABSORBER .............................. 160
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 162
SUBSTANCES.................................................................... 165
x..................................................................... 132
x .................................................... 133
x................................................ 134
x...................................................... 136
x................................................... 136
x ............................................ 138
CONTENTS 6
AUXILIARY SUBSTANCES................................................... 168
STANDARDS...................................................................... 170
INDEX ............................................................................... 171
MEANS OF REPRESENTATION 7
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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
Marke™ Identifies a brand in merchandise traffic.
Identifies a protected name.
IMPORTANT NOTES 8
,03257$17127(6
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
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 9
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 currentbKTMbPowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ Always place the vehicle on a firm and even surface.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದ Do not place the vehicle where there are flammable or explosive substances.
ದ Switch off the engine and remove the ignition key.
ದ 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 10
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
ದ 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 11
ದ 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
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View 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
View of vehicle, rear right side
600638-10
VIEW OF VEHICLE 15
1 Ignition/steering lock
2 Light switch, flasher switch, horn
3 Rear mirror
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Throttle grip
7 Chassis number
8 Rear brake caliper
9 Passenger footrest
10 Shock absorber rebound damping
11 Foot brake pedal
12 Engine oil level viewer
LOCATION OF SERIAL NUMBERS 16
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Chassis number
The chassis numberb is stamped on the steering head on the right.
100217-10
Type label
Type labelb is located on the upper right frame tube below the seat.
100218-10
LOCATION OF SERIAL NUMBERS 17
Key number
The key numberb can be found on thebKEYCODECARD.
Info
You need the key number to order a spare key. Keep thebKEYCODECARD in a safe
place.
100179-10
Engine number
The engine numberb is stamped on the left side of the engine under the engine sprocket.
600479-10
LOCATION OF SERIAL NUMBERS 18
Fork part number
The fork part numberb is stamped on the inner side of the fork stub.
600480-10
Shock absorber part number
Shock absorber part numberb can be viewed from the right side.
100216-10
OPERATING ELEMENTS 19
23(5$7,1*(/(0(176
Clutch lever
The clutch leverb is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
600481-10
Hand brake lever
The hand brake leverb is located on the right side of the handlebar and operates the front
wheel brake.
The hand brake lever operates the front brake.
600598-11
OPERATING ELEMENTS 20
Light switch
The light switchb is fitted on the left side of the handlebar.
Possible states
Low beam on ದbLight switch is turned downwards. In this position, the low
beam and tail light are switched on.
High beam on ದbLight switch is turned upwards. In this position, the high
beam and the tail light are switched on.
500020-01
Light switch
The light switchb is fitted on the left side of the handlebar.
Possible states
Low beam on ದbLight switch is turned downwards. In this position, the low
beam and tail light are switched on.
High beam on ದbLight switch is turned upwards. In this position, the high
beam and the tail light are switched on.
100222-10
OPERATING ELEMENTS 21
Headlight flasher switch
The headlight flasher switchb is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in neutral position
• Headlight flasher switch pressed ದbIn this position, the headlight flasher (high beam)
is actuated.
500020-11
Flasher switch
The flasher switchb is fitted on the left side of the handlebar.
Possible states
Flasher light off
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
Flasher light, right, on ದbFlasher 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 22
Flasher switch
The flasher switchb is fitted on the left side of the handlebar.
Possible states
Flasher light off
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
Flasher light, right, on ದbFlasher 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
Horn
The horn buttonb is fitted on the left side of the handlebar.
Possible states
• Horn buttonb in neutral position
• Horn buttonb pressed ದbThe horn is operated in this position.
500021-11
OPERATING ELEMENTS 23
Horn
The horn buttonb is fitted on the left side of the handlebar.
Possible states
• Horn buttonb in neutral position
• Horn buttonb pressed ದbThe horn is operated in this position.
100224-10
Emergency OFF switch
The emergency OFF switchb is fitted on the left side of the handlebar.
Possible states
Emergency OFF switch off ದbIn this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
Emergency OFF switch on ದbThis position is necessary for operation as the
ignition circuit is closed.
100225-10
OPERATING ELEMENTS 24
Electric starter button
The electric starter buttonb is fitted on the right side of the handlebar.
Possible states
• Electric starter buttonb in basic position
• Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.
100226-10
Ignition/steering lock
The ignition/steering lockb is located in front of the seat.
Possible states
Ignition off ದbIn 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 ದbIn this position, the ignition circuit is closed, and the engine
can be started.
Steering locked ದbIn this position, the ignition circuit is interrupted and the
steering locked. The ignition key can be removed.
100221-10
OPERATING ELEMENTS 25
Combination instrument
The combination instrument is attached in fromt of the handlebar.
The combination instrument is divided into 4 function areas.
bFunction buttons
Tachometer
Indicator lights
Display
700116-01
Combination instrument - function buttons
Press thebMODEbbuttonb to change the display mode.
Possible display modes are total distance covered (ODO), tripmasterb1b(TRIPb1) and tripmasterb2b(TRIPb2).
Press thebSETbbuttonb
Buttonb
has no function.
to reset tripmasterb1b(TRIPb1) and tripmasterb2b(TRIPb2)tob0.0.
700117-01
OPERATING ELEMENTS 26
Combination instrument - tachometer
The tachometerb displays the engine speed in revolutions per minute.
The red markingb
100118-10
Combination instrument - control lamps
The indicator lamps provide additional information on the operating state of the motorcycle.
Possible states
shows the excess engine speed range.
Flashing indicator flashes green in flash rhythm ದbFlasher light is switched
on.
Idling speed indicator lamp lights up green ದbTransmission is in neutral.
High beam indicator lamp lights up blue ದbHigh beam is switched on.
100119-10
Temperature warning lamp lights up red ದbCoolant has reached a critical
value.
Fuel level warning lamp lights up orange ದbFuel level has reached the reserve
mark. Display switches tobTRIPbF.
FIbwarning lampb(MIL) lights/flashes orange ದbThe OBD has detected an
emission- or safety-critical error.
OPERATING ELEMENTS 27
Battery warning lamp lights up ದbVoltage in electrical system too low.
Combination instrument - Display
When you switch on the ignition, all display segments light up for a second as a function
test.
700118-01
LEnGTth
Following the display function test, the wheel circumferencebLEnGth is shown for one second.
Info
1870 mm corresponds to the circumference of the 17" front wheel with a series production tire.
700119-01
The display then changes to the last selected mode.
OPERATING ELEMENTS 28
Combination instrument - speed display
The speedb is displayed in kilometers per hourbkm/h or miles per hourbMph.
700114-01
Setting 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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