KTM 2004 660 SMC User manual

9/2003 FOTO: MITTERBAUER
OWNER`S MANUAL
MANUALE D`USO
MANUEL D`UTILISATION
MANUAL DE INSTRUCCIONES
ART.NR: 3.211.18
660 SMC
BEDIENUNGSANLEITUNG2004

ENGLISH
1
IMPORTANT
WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL
CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST
RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND
ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE
PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR
ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:
 WARNING 
IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR
BODY AND YOUR LIFE.
! CAUTION !
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE
IS NOT ROAD-SAFE ANYMORE.
Please insert the serial numbers of your motorcycle in the boxes below
Frame number
Engine number
Key number
Stamp of dealer
Tampering with noise control system prohibited
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes of
maintenance, repair or replacement, of any device or element of design incorporated into
any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; and
(b) the use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
COMSUMER INFORMATION FOR AUSTRALIA ONLY
KTM-S PORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATIONS , COLORS ,
MATERIALS , SERVICES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PRE -
VIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS , OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING
THEM WITH OTHERS
. I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I NTHE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .

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2
Introduction
We would like to congratulate you on your purchase of a KTM motorcycle.
You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring
you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
Before you go for your first ride, be sure to read this manual carefully and thoroughly in
order to familiarize yourself with how to operate your new motorcycle and with its
characteristics, even if this means that you will have to dedicate some of your valuable
time to this task. Only by doing so will you learn how to tune your motorcycle to your
specific needs and how to protect yourself against injury. Besides, this manual contains
important information on motorcycle maintenance. At the time this manual was typeset,
it was up-to-date with the latest state of this production series. It cannot be completely
ruled out, however, that minor discrepancies may exist resulting from further design
upgrades of these motorcycles.This manual is an important part of your motorcycle and
should be passed on to any subsequent owner in case you decide to sell it.
We expressly point out that work marked with an asterisk in the chapter "Maintenance
work on the chassis and engine" must be performed. If maintenance work should
become necessary during a competition it should be performed by a trained mechanic.
KTM strongly recommends that all service work to your KTM should be performed by a
qualified KTM dealer.
For your own safety, use KTM-approved parts and accessories only. KTM is not liable
for damage that arises in connection with the use of other products.
Take special care to follow the recommended run in, inspection, and maintenance
intervals. Heeding these guidelines will significantly increase the life of your motorcycle.
To ensure that all work to your KTM is performed properly and to avoid warranty
conflicts, KTM recommends that you always have your KTM serviced by a recognized
and qualified KTM dealer.
Off-road motorcycle driving is a wonderful sport and we hope that you will be able to
enjoy it to the full. It may, however, involve potential problems for the environment or
lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle
is used responsibly. To safeguard the future of motorcycle sports, make sure that you use
the motorcycle in accordance with the law, show that you are environmentally conscious
and respect the rights of others.
We wish you a lot of fun when driving !
KTM-SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments: Spare parts manual chassis & engine
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM-SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3
IMPORTANT LIMITED WARRANTY AND
LIMITED GUARANTEE INFORMATION
The KTM 660 SMC is designed and constructed to resist the usual wear and
tear of normal use in competitions.
The motorcycles comply with the regulations and categories currently in
effect with the leading international motorcycle associations.
The service, care and operating instructions for the engine and chassis
specified in the owner's manual must be observed to ensure that the bike
runs smoothly and to avoid premature wear. An improperly tuned chassis can
lead to damage and breakage of the chassis components.
The service work specified in the "Lubrication and Maintenance Schedule"
must be performed and service records must be kept for warranty
documentation. Lack of proper service and maintenance records or
documentation could void warranty.
The fuels and lubricants specified in the owner's manual or those of an equal
quality must be used in accordance with the maintenance schedule.
The warranty or guarantee shall become void for damage and consequential
damage caused by manipulations or conversions to the motorcycle.
The use of the motorcycle under extreme conditions, e.g. on extremely
muddy and wet terrain, can lead to higher than average wear on
components such as the drive train or the brakes. In this case it may become
necessary to service or replace wear parts before the service limit specified in
the maintenance schedule has been reached.
The SMC models are only allowed on public roads in the original
homologated (throttled) version. Without this performance restriction (i.e.
dethrottled), these models are only allowed to be driven in Supermoto
competitions but not on public roads.
No warranty will be assumed if the bike is used in races or competitions.
In accordance with the international quality management
ISO 9001 standard, KTM uses quality assurance processes
that lead to the highest possible product quality.

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4
Page
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, Engine type . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand decompression lever . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . .6
Tripmaster switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Activating/deactivating the display modes . . . . . . . . .10
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . .11
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Emergency OFF switch (Australia) . . . . . . . . . . . . . . . .11
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Hot start device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Handlebar lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Compression damping of fork . . . . . . . . . . . . . . . . . . .13
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . .13
Compression damping of shock absorber . . . . . . . . . .13
Rebound damping of shock absorber . . . . . . . . . . . . .13
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Instructions for initial operation . . . . . . . . . . . . . . . . . .14
Running in the LC4 models . . . . . . . . . . . . . . . . . . . . .14
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . .14
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . .15
Check the following before each start . . . . . . . . . . . . .15
Starting when the engine is cold . . . . . . . . . . . . . . . . .16
Starting when the engine is warm or hot . . . . . . . . . . .16
What to do when the engine is “flooded” . . . . . . . . .16
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . .17
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
PERIODIC MAINTENANCE SCHEDULE 2004 . . . . . . . . . .18
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .20
Removal of seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Check and adjust steering head bearing . . . . . . . . . . . .21
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . .21
Cleaning the dust sleeves of the telescopic fork . . . . . .21
Basic suspension setup for the weight of the driver . . .22
Changing the spring preloading of the shock absorber 23
Checking rubber ring on the WP rear shock absorber .24
Lubricate rear suspension linkage . . . . . . . . . . . . . . . .24
Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . .24
Page
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . .25
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General information about KTM disc brakes . . . . . . . .26
Changing the basic position of the handbrake lever . .27
Checking of brake fluid level - front brake . . . . . . . . .27
Refilling the front brake fluid reservoir . . . . . . . . . . . .27
Checking the front brake pads . . . . . . . . . . . . . . . . . .27
Replacing the front brake pads . . . . . . . . . . . . . . . . . .28
Check the rear brake fluid level . . . . . . . . . . . . . . . . .28
Refilling the rear brake fluid reservoir . . . . . . . . . . . . .28
Changing the basic position of the brake pedal . . . . . .29
Checking the rear brake pads . . . . . . . . . . . . . . . . . . .29
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .29
Dismounting and mounting the front wheel . . . . . . . .30
Dismounting and mounting the rear wheel . . . . . . . . .30
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . .31
Checking the shock absorption rubbers in the rear hub 31
Check/set distance of the magnetic sensor . . . . . . . . .32
Replacing the battery in the electronic speedometer . .32
Replacing the fan fuse . . . . . . . . . . . . . . . . . . . . . . . . .32
Replacing headlight lamp/parking light lamp . . . . . . .33
Exchanging the brake light and tail light bulb . . . . . . .33
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Checking the coolant level . . . . . . . . . . . . . . . . . . . . .34
Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . . .35
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . .36
Checking the adjustment of the hand decompression cable 36
Changing the original position of the clutch lever . . . .36
Checking the oil level of the hydraulic clutch . . . . . . .37
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . .37
Draining the float chamber of the carburetor . . . . . . .37
Carburator – Adjust idling . . . . . . . . . . . . . . . . . . . . . .38
Adjusting the mixture control screw . . . . . . . . . . . . . . .38
Checking the float level (float height) . . . . . . . . . . . . .38
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Checking the engine oil level . . . . . . . . . . . . . . . . . . . .39
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Oil and screen filter change, bleeding of the oil system 40
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
CONSERVATION FOR WINTER OPERATION . . . . . . . . .44
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RE-INITIATION AFTER TIME OF STORAGE . . . . . . . . . . .44
TECHNICAL SPECIFICATIONS – ENGINE 660 SMC . . . .45
TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC . . .46
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . .APPENDIX
Index

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5
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Write this number into the relevant area on page 1.
Engine number, engine type
The engine number and engine type are stamped on the right hand side of
the engine below the chain sprocket. Write this number into the relevant
area on page 1.
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The
adjusting screw Ais used to change the original position of the clutch lever
(see maintenance work on chassis and engine).
Hand decompression lever
The hand decompression lever 2is only used in two special cases:
a)When the engine stalled.
It is possible that the starter motor is not able to crank the engine on the
next attempt. This is due to the fact that the automatic decompressor
doesn’t work properly. If this happens, pull the manual decompression
lever and start again. Afterwards normal starting will be possible.
b) When you want to push the motorcycle.
While pushing, pull the hand decompression lever to make it easier to get
the engine going.
Hand brake lever
The hand brake lever 3is mounted on the right side of the handlebar.The
basic position of the handbrake lever can be changed in 4 steps
(see Maintenance work on chassis and engine).
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
A
1
2
3

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6
Indicator lamps
The green control lamp 1flashes when the indicator is working in
the same rhythm as the flashing indicator.
The blue control lamp 2lights up when the high beam is on.
Electronic speedometer
The electronic speedometer display is activated as soon as the engine is
switched on and the motorcycle starts to move.
The engine must be started in order for the speedometer to be supplied
with electricity from the generator. The display is not activated until the
front wheel has made 1 revolution (impulse for speedometer).
TEST
All of the display elements will light up for 1 second for the function test.
WS (wheel size)
The display will change and briefly show the diameter of the front wheel in
millimeters.
If the front wheel does not turn, the display will automatically change to the
SPEED/H mode.
If the front wheel turns, the display will automatically change to the SPEED
/ODO mode.
SPEED/H (hours) display mode
When you stop driving and no impulses are sent from the wheel sensor, the
display mode will automatically change from SPEED/ODO to SPEED/H. H
shows the operating hours. The operating hour counter starts to count as
soon as you start the engine. The displayed figure cannot be cleared.
Service intervals are indicated in operating hours for some KTM offroad
motorcycles, making the operating hour counter a very practical function.
SPEED/ODO display mode
The SPEED/ODO mode shows the speed and the total kilometers traveled.
When the front wheel stops turning, the display will automatically change
to the SPEED/H mode.
The information will disappear in the display when the front wheel stops
turning for 1 minute.
1
2

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7
Tripmaster switch
The switch has 3 buttons: MODE, + (plus) and – (minus).
The switch can also be mounted on the outer end of the handlebar with a
clamp (SP.NO. 583.14.069.350).

WARNING

DONOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR
ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN
ACCIDENT.
Electronic speedometer functions provided by the Tripmaster
switch
The display modes on the electronic speedometer will change in the
following order. If not, please read the chapter "ACTIVATING AND
DEACTIVATING THE DISPLAY MODE."
SPEED/ODO display mode
SPEED displays the speed in KPH or MPH. The displayed figure cannot be
cleared.
ODO displays the kilometers or miles traveled. The displayed figure cannot
be cleared.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to change to the next mode
SPEED/MAX display mode
MAX displays the maximum speed. It is always active.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0
SPEED/LAP display mode
LAP displays the stopped lap time in hours, minutes and seconds.
+ BUTTON Starts and stops the stop watch. The lap time is not reset to 0.
– BUTTON Stops the running stop watch, stores the lap time and restarts
the stop watch. The time is reset to 0. A total of 10 lap times
can be stored and read in the SPEED/LAP display mode. To
clear all of the stored lap times, hold the MODE button for 3
seconds in the SPEED/LAP mode.
press the MODE BUTTON to change to the next mode
If no lap time is stored or the motorcycle is driving, the LAP/LAP
mode will be skipped.
press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all
stored lap times to 0
LAP/LAP display mode
The lap number is shown at the top and the lap time in hours, minutes and
seconds at the bottom of the display.
If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will
be skipped.
Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the
stored lap times.
+ BUTTON changes to the next lap time.
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to change to the next mode
+
–
MODE

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8
SPEED/CLK (clock) display mode
CLK will display time in hours, minutes and seconds.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode.
press and hold the MODE BUTTON 3 SECONDS to set the time in the menu
(see SETTING THE CLOCK)
SPEED/H (hours) display mode
When you stop driving and no impulses are sent from the wheel sensor, the
display mode will automatically change from SPEED/ODO to SPEED/H. H
shows the operating hours. The operating hour counter starts to count as
soon as you start the engine. The displayed figure cannot be cleared.
Service intervals are indicated in operating hours for some KTM offroad
motorcycles, making the operating hour counter a very practical function.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to change to the SETUP mode
(see REVEALING/CONCEALING functions).
SPEED/TRP1 (trip 1) display mode
The TRP1 trip meter is always active and counts to 999.9. It is used to
measure the length of a trip or the distance between 2 refueling stops.
TRP1 is linked to AVS1 and STP1. The calculation of these figures is
activated by the first impulse received from the wheel sensor (when the
front wheel starts to turn) and stops 3 seconds after the last impulse is
received (when the front wheel has stopped).
The TRP1, AVS1 and STP1 figures are automatically reset to 0 after passing
999.9.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode.
press and hold the MODE BUTTON 3 SECONDS to automatically reset the
TRP1, AVS1 and STP1 figures to 0.
SPEED/AVS1 (average speed 1) display mode
AVS1 is always active and shows the average speed based on the TRP1 and
STP1 figures. The calculation of this figure is activated by the first impulse
received from the wheel sensor and stops 3 seconds after the last impulse is
received.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and
STP1 figures to 0.
SPEED/STP1 (stop 1) display mode
STP1 shows the traveling time based on TRP1 and continues to count
whenever it receives impulses from the wheel sensor. The calculation of this
figure is activated by the first impulse received from the wheel sensor and
stops 3 seconds after the last impulse is received.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to reset the TRP1, AVS1 and
STP1 figures to 0.

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9
SPEED/TRP2 (trip 2) display mode
The TRP2 trip meter is always active and counts to 999.9. Contrary to
TRP1, the displayed figure can be changed using the + and – buttons. This
is a very useful function for trips taken according to a roadbook.
TRP2 is activated by the first impulse received from the wheel sensor and
stops automatically 3 seconds after the last impulse is received.
+ BUTTON increases the TRP2 figure
– BUTTON decreases the TRP2 figure
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to reset TRP2 to 0
SPEED/AVS2 (average speed 2) display mode
AVS2 shows the average speed based on the TRP2 and STP2 figures. The
calculation of this figure is activated by the first impulse received from the
wheel sensor and stops 3 seconds after the last impulse is received.
The displayed figure will deviate from the actual average speed if TRP2 was
changed manually or if STP2 was not stopped after the trip.
+ BUTTON no function
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to change to the next mode
SPEED/STP2 (stop 2) display mode
STP2 is a manual stop watch. Start the stop watch by pressing the + but-
ton, press again to hold. Press again to continue timing.
Press the MODE button to change to the next mode. The STP2 display will
blink in the other modes if STP2 continues to run in the background. To
stop STP2, return to the SPEED/STP2 mode and press the + button.
+ BUTTON starts and stops the stop watch
– BUTTON no function
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to reset STP2 figures to 0
Setting the clock
To set the clock, switch the ignition off and select the SPEED/CLK mode.
Press and hold the MODE button for 3 seconds. The blinking digits can be
changed using the + and – buttons. Press the MODE button to move to the
next digit.
If no button is pressed for 20 seconds, the settings will be stored
automatically and the display will return to the SPEED/CLK mode.
+ BUTTON time +
– BUTTON time –
press the MODE BUTTON to change to the next digit
press and hold the MODE BUTTON 3 SECONDS to store the time and return to
the SPEED/CLK mode
Kilometers or miles
The unit (kilometers or miles) can also be changed. The ODO figure will be
retained and converted accordingly. The TRP1, AVS1, STP1, TRP2 and
AVS2 figures will be cleared.
To select the unit, select the SPEED/H mode and hold the MODE button for
3 seconds to access the SETUP menu. Press the MODE button 10 times
until the KMH/MPH function blinks. Press the + button to move to the
options. Press the + button for KMH or the – button for MPH. If no button
is pressed for 20 seconds, the setting will be stored automatically and the
display will return to the SPEED/H mode.
The setting can be stored immediately by holding the MODE button for a
few seconds until the display returns to the SPEED/H mode.
+ BUTTON to access the menu
to activate the KMH setting
– BUTTON to activate the MPH setting
press the MODE BUTTON to change to the next mode
press and hold the MODE BUTTON 3 SECONDS to store the setting and return
to the SETUP menu

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10
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
no function
no function
starts / stops LAP
figure LAP remains
next figure
no function
no function
no function
no function
no function
increases TRP2 figure
no function
starts / stops STP2
Press +
Display
SPEED / ODO
SPEED / MAX
SPEED / LAP
LAP / LAP
SPEED / CLK
SPEED / H
SPEED / TRP1
SPEED / AVS1
SPEED / STP1
SPEED / TRP2
SPEED / AVS2
SPEED / STP2
OVERVIEW OF TRIPMASTER FUNCTIONS
Standing motorcycle Driving motorcycle
Press –Press MODE Hold MODE for 3 sec
no function
no function
stops LAP, stores LAP
figure, resets LAP to 0
no function
no function
no function
no function
no function
no function
decreases TRP2 figure
no function
no function
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
no function
resets MAX to 0
clears all LAP figures
next display mode
set clock menu
display setup menu
resets TRP1, STP1 and
AVS1 to 0
resets TRP1, STP1 and
AVS1 to 0
resets TRP1, STP1 and
AVS1 to 0
resets TRP2 to 0
next display mode
sets STP2 to 0
Activating/deactivating the display modes
It may not be necessary to display all of the display modes (functions) at the
same time. It is possible to conceal any information not currently required.
By deactivating certain functions, the MODE button will only allow you to
select from the activated modes.
In the SPEED/H mode, press and hold the MODE button for 3 seconds to
access the SETUP menu. The blinking function can be activated by pressing
the + button and deactivated by pressing the – button.
If no button is pressed for 20 seconds, the setting will be stored
automatically and the display will return to the SPEED/H mode.
+ BUTTON activates the blinking display
– BUTTON deactivates the blinking display
press the MODE BUTTON to change to the next display without changing
any settings
press and hold the MODE BUTTON 3 SECONDS to store the settings and
change to the SPEED/H mode

ENGLISH
11
Combination switch
The light switch has 3 switch positions.
A= Light off
B= Low beam light
C= High beam light
The red short circuit button 1serves to switch off the engine. Leave the
switch pressed, until the engine stops. With the button 2the horn will
sound.
Flasher switch
The flasher switch is a separate unit and is mounted on the left portion of
the handlebar.
The wire harness is designed in a way that whenever you want to use your
bike off-road, you can dismount the entire turn indicator system without
affecting the function of the remaining electrical system.
Flasher left
Flasher right
Emergency OFF switch (Australia)
The emergency OFF switch 5is located next to the throttle grip. Primarily
designed as safety or emergency OFF switch, it should normally not be in its
activated state.
In this position, the ignition circuit is shorted; if the engine is running,
it will stall immediately, if it is at standstill, it will not start.
In this position, the ignition circuit is enabled; the engine should start.
Filler cap
To open filler cap: Turn the filler cap counter-clockwise.
To close filler cap: Screw on the filler cap clockwise.
Install tank breather hose 3without kinks.
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carburetor.
ON When using the motorcycle, the rotating handle must be set to the
ON position. Now fuel may flow to carburetor. In this position the
tank empties down to the fuel reserve of approx. 2,5 liters.
RES The reserve tank, approximately 2,5 liters, cannot be tapped until the
rotating handle is turned to the RES position. Fill the tank as soon as
possible and remember to turn the rotating handle back to the ON
position so that you will have backup fuel next time, too.
A
B
C
1 2
3
4

ENGLISH
12
Choke
If you pull the choke button 1out as far as possible, a bore in the
carburetor will be opened through which the engine may take in additional
fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts.
To deactivate the choke, push the choke button back into its basic position.
Hot start device
If you pull the hot start device 2out as far as possible, a bore in the
carburetor will be opened through which the engine may take in additional
air. The result is a „lean“ fuel-air mixture of the type needed for hot starts.
To deactivate the hot start device, push the hot start button back into its
basic position.
Shift lever
The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral position is located between first
and second gear.
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can
be swivelled.
Foot brake pedal
The foot brake pedal is located in front of the right foot rest. Its basic
position can be adjusted to your seat position (see maintenance work).
2,3,4,5
1
N
1
2

ENGLISH
13
Handlebar lock
The handlebar can be locked by means of the lock located on the control
head. Fully turn handlebar to right to lock, insert key, turn to left, press in,
turn to right and withdraw.
!
CAUTION
!
NEVER LEAVE THE KEY INSERTED IN THE LOCK. IFYOU TURN THE STEERING TO THE LEFT
THE KEY COULD GET DAMAGED.
Compression damping of fork
The compression damping is to be set at the lower end of the fork tubes. It
only regulates the degree of damping during compression. Remove closing
cap A. By using the knob 1(COM), the degree of damping of the
compression can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during compression.
STANDARD ADJUSTMENT:
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
WP 1418Y750 ..................... 20 clicks
Rebound damping of fork
Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the knob 2,the degree of damping of the rebound
can be adjusted. Turn the knob clockwise to increase damping, turn it
counterclockwise to reduce damping during rebounding.
STANDARD ADJUSTMENT:
–turn adjusting screw clockwise as far as it will go
–turn it back by as many clicks as are specified for the relevant type of fork
WP 1418Y750 ..................... 15 clicks
Compression damping of shock absorber
With the knob 3the degree of damping of the compression can be
adjusted. Turn the knob counterclockwise to increase damping, turn it
clockwise to reduce damping during rebounding.
STANDARD ADJUSTMENT:
WP 0118Y733 ................... position 4
Rebound damping of shock absorber
With the setting wheel 4the degree of damping of the rebound can be
adjusted. Turn the knob to the left side to increase damping, turn it to the
right side to reduce damping during rebounding.
STANDARD ADJUSTMENT:
WP 0118Y733 ................... position 8
A
1
2
2
3
4

ENGLISH
14
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE
Instructions for initial operation
–Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
–Read these operating instructions carefully before your first
ride.
–Enter the chassis, engine and key numbers on page 1.
–Familiarize yourself with the operating elements.
–Adjust the hand brake lever and foot brake lever to your
most comfortable position.
–Get used to handling the motorcycle on an empty parking
lot or open space, before starting on a longer drive. Also try
to drive as slowly as possible and in standing position, to
improve your feeling for the vehicle.
–Do not drive along off-road tracks which go beyond your
abitily and experience.
–Hold the handlebars with both hands and leave your feet on
the foot rests while driving.
–Remove your foot from the foot brake lever when you are
not braking. If the foot brake lever is not released the brake
pads rub continuously and the braking system is
overheated.
–Do not make any alterations to the motorcycle and always
use ORIGINAL KTM SPARE PARTS. Spare parts from other
manufacturers can impair the safety of the motorcycle.
–Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be
secured as close as possible to the middle of the vehicle;
distribute the weight evenly between the front and rear
wheel. Never exceed the maximum permissible laden
weight and the axle weights. The maximum permissible
laden weight is made up of the following components:
–Motorcycle ready for operation and tank full
–Luggage
–Driver with protective clothing and helmet.
–Pay attention to running-in procedure.
Running in the LC4 models
Even very precisely machined sections of engine components
have rougher surfaces than components which have been
sliding against one another for quite some time. Therefore,
every engine needs to be broken in. For this reason, during its
first 1000 kilometers (620 miles) the engine must not be
revved up to its performance limits. The engine speed of 4800
r.p.m. must not be exceeded during the first 1000 kilometers
(620 miles). During this break-in time, you should ride your
motorcycle in different conditions (roads, easy off-road
terrain). The following table shows you the maximum velocity
values in the different gears at 4800 r.p.m. as based on the
rear wheel transmission ratio of your motorcycle.
NOTE:
DURING THE STAGE OF RUNNING THE ENGINE IN, THAT IS THE FIRST
1000 KM (620 MILES), THE ENGINE OIL USED SHOULD BE OF A
MINERAL OIL FORMULA. THIS ALSO APPLIES IF THE ENGINE HAS BEEN
REPAIRED.
 WARNING 
–W
EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER
KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A
JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A
SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY
COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS
POSSIBLE.
–D
ONOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–A
LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS
BECOME AWARE OF YOU AS EARLY AS POSSIBLE.
–ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR
EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF
THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE
WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING
PROPERTIES.
–D
RIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF
EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY OPERA-
TING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED WHEN THE
TIRES ARE WARM.
–T
HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY
WITH TIRES THAT HAVE THE SAME PROFILE TYPE.
–N
EW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY
MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PURPOSE, RIDE THE
MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST
200 KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT DIFFE-
RENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED.
TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL
THEY ARE PROPERLY RUN IN.
–O
BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING
TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE.
–C
HOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.
–RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR
GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY
SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR
GOGGLES, THE OPERATOR WILL BE BLINDED.
–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE
ENGINE IS RUNNING.
–T
HESE MOTORCYCLE WERE DESIGNED AND BUILT FOR ONE PERSON
ONLY - NO ADDITIONAL PASSENGER ALLOWED!
–W
HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT
OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.
Accessories and payload
Accessory parts and baggage can significantly decrease a
motorcycle's driving stability. Please observe the following
warnings.
 WARNING 
–IFYOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFACTU-
RER'SRECOMMENDED MAXIMUM PAYLOAD.
–F
ASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTORCYCLE
AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR
WHEELS AND ON THE LEFT AND RIGHT.
–BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND; LOOSE
BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY.
–A
HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'SHANDLING AND
CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT YOUR
DRIVING SPEED ACCORDINGLY.
660 SMC
16:38 Z
1. G 35 kmh
2. G 55 kmh
3. G 80 kmh
4. G 95 kmh
5. G 110 kmh
gear
ratio

ENGLISH
15
Check the following before each start
When you start, the motorcycle must be in perfect mechanical condition.
For safety reasons, you should make a habit of performing an overall check
of your motorcycle before each start.
The following checks should be performed:
1 CHECK OIL LEVEL
Insufficient oil results in premature wear and consequently to engine
damage.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the filler cap,
check that the tank venting hose is free of kinks.
3 CHAIN
A loose chain can fall from the chain wheels; an extremely worn chain
can tear, and insufficient lubrication can result in unnecessary wear of
chain and chain wheels.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must be replaced.
The tread depth must comply with the legal regulations. Also check the
air pressure. Insufficient tread and incorrect air pressure deteriorate the
driving performance.
5 BRAKES
Check correct functioning of the braking system. Check for sufficient
brake fluid in the reservoir. The reservoirs have been designed in such a
way that brake fluid does not need to be refilled even when the brake
pads are worn. If the level of brake fluid falls below the minimum value,
this indicates a leak in the braking system or completely worn out brake
pads. Arrange for the braking system to be checked by a KTM specialist,
as complete failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at hand brake lever and foot brake lever.
6 CABLES
Check correct setting and smooth operation of all control cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
8 ELECTRICAL SYSTEM
Check correct operation of headlamps, tail-lights, brake lights, indicators,
control lamps and horn while the engine is running.
9 LUGGAGE
If you are taking luggage with you, check that this is securely fastened.
DRIVING INSTRUCTIONS

ENGLISH
16
Starting when the engine is cold
1Open the fuel tap 1
2Swing up the side stand
3Put the gear in neutral
4Operate the choke 2
5Turn on the emergency OFF switch 4
6Go to the left of your motorbike. DO NOT open the throttle, and briskly
kick the kickstarter ALL THE WAY.
 WARNING 
–I
FYOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY
MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE
KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PUSH YOUR FOOT UPWARD WITH
GREAT VEHEMENCE.
–A
LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.
KICKING THE KICKSTARTER WITH LESS ENOUGH FORCE AND AN OPENED THROTTLE
INCREASE THE KICK-BACK HAZARD.
–D
ONOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
! CAUTION !
–BEFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE SIDE STAND.
–D
ON’TRIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS
COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED
CYLINDER, IT CAN CAUSE ENGINE DAMAGE.
Starting when the engine is warm or hot
1 Open the fuel tap 1
2Swing up the side stand
3Put the gear in neutral
4Push the hot start button 3
5Turn on the emergency OFF switch 4
6Go to the left of your motorbike. DO NOT open the throttle, and briskly
kick the kickstarter ALL THE WAY.
What to do when the engine is “flooded”
In the event of a fall, more fuel than necessary may get into the engine. In
order to "pump the engine free", pull the hand decompression lever, fully
rev up the engine, actuate the kickstarter 5 to 10 times. Then, start the
engine as described above. If the engine fails to start, unscrew the spark
plug and dry it.
NOTE:
The carburetor has an accelerator pump. Every time you open the throttle,
fuel will be injected into the intake passage. When starting, be sure that you
open the throttle completely only once.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly release the clutch
lever and open throttle at the same time.
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear. Depending
on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close
throttle, at the same time pull clutch lever in and shift to the next higher
gear. Let clutch lever go again and open throttle. If you turned on the
choke, make sure you turn it off again as soon as engine is warm.
When you reach full speed through opening the throttle all the way, turn
throttle back to 3/4; the speed will not decreases but the engine will use less
fuel.
Only give as much throttle as the engine can handle. Through quick and
high reving of throttle, the fuel consumption increases. When shifting
down, use the brakes if necessary and close throttle at the same time. Pull
clutch lever and shift down to the next gear. Let clutch lever go slowely and
open throttle or shift down again.
1
2
3
4

ENGLISH
17
! CAUTION !
–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE.
–N
EVER PARK YOUR MOTORCYCLE IN FIRE HAZARDOUS PLACES DUE TO
DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.
INFORMATION ABOUT THE SIDE STAND:
Use your foot to push the side stand forward as far as possible,
and lean your motorcycle to the side. Make sure that your
motorcycle is standing safely on solid ground. Just in case, you
can also put in a gear.
! CAUTION !
THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE
ONLY. IFYOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN
ADDITIONAL LOAD ONTO THE SIDE STAND, YOU MAY CAUSE DAMAGE TO
THE SIDE STAND OR THE FRAME, AND YOUR MOTORBIKE MAY FALL OVER.
Fuel
The LC4 engine needs premium gasoline with an octane
number of 95 (ROZ) or higher (USA = Premium RON 91).
! CAUTION !
USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES).
NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT
MAY DAMAGE THE ENGINE.
 WARNING 
GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION
SHOULD BE USED WHEN HANDLING GASOLINE. DONOT REFUEL THE
MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS
SWITCH OFF THE ENGINE BEFORE REFUELLING. BECAREFUL NOT TO SPILL
GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IFGASOLINE IS SWALLOWED OR SPLASHED IN
THE EYES, SEEK A DOCTOR’SADVICE IMMEDIATELY.
Fuel expands when its temperature rises. Therefore do not fill
the tank to the top (see fig.).
 WARNING 
–AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND
ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE
CONTROL OF YOUR MOTORCYCLE.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
–ABENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO
STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS
STABILITY.
! CAUTION !
–HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WERECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES TO WARM
UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE
TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS
SOON AS THE RADIATORS BECOME WARM.
–NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
ALOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE VALVES.
INADDITION, THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL.
–L
ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN
LEAD TO MOTOR DAMAGE.
–I
FANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT
THE ENGINE FASTENING BOLTS ARE TIGHT.
–I
NTHE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU
NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP
IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED
KTM DEALER.
Braking
Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with care, blocking
wheels can cause you to skid or fall. Also change down to
lower gears depending on your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.
 WARNING 
–WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER
AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE
WEAKER THE BREAKING EFFECT. INEXTREME CASES, THE ENTIRE
BRAKING SYSTEM CAN FAIL.
–I
N CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES
THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS,
HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE
BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN.
–R
IDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE
BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.
–DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To stop
the engine, switch off the ignition or pull the short circuit
button when the engine is idling, until the engine stops. Turn
the fuel tap to the OFF position, park on an area with firm
ground, and lock the motorcycle.
 WARNING 
–ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL
SURFACE.
–M
OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DONOT TOUCH ANY OF
THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO
PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET
BURNED.
–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
35 mm

ENGLISH
18
after / every
2500 km
or
25 hours
1. Service after
1000 km
or
10 hours
after / every
5000 km
or
once a year
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
S ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM .
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and fine filter ●●●
Clean oil screens and magnet of drain plug ●●●
Check oil lines for damage and kink-less arrangement ●●
Check and adjust spark plug, replace every 10,000 km ●
Check and adjust valve clearance ●●
Check engine fastening screws for tight fit ●●
Make sure all engine screws accessible from the outside are screwed tight ●●
Check carburetor connection boots for cracks and leaks ●
Check idle setting ●●
Check bleeder hoses for damage and kink-free arrangement ●●
Check cooling system for leaks, antifreeze protection ●●
Check exhaust system for leaks and suspension ●●
Check actuating cables for damage, smooth operation, and kink-less ●●
arrangement, adjust and lubricate
Check fluid level of the clutch master cylinder ●
Clean air filter and air filter box ●
Check cables for damage and kink-less arrangement ●
Check headlamp adjustment ●
Check electrical system for function; (low/high beams, stop light, turn indicators, ●●
tell-tale lamps, horn, emergency-off switch)
Make sure all screws and nuts are tight ●●
Check brake fluid level, lining thickness, and brake discs ●●
Check brake lines for damage and leaks ●●
Check/adjust smooth operation, free travel of handbrake/footbrake levers ●●
Check screws of brake system for tight fit ●●
Check suspension strut and fork for leaks and proper function ●●
Check O-ring of suspension strut for wear ●
Clean dust sleeves ●
Bleed fork legs ●●
Check swinging-fork pivot ●
Check/adjust steering-head bearing ●●
Lubricate reversing lever ●
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, ●●
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join ●●
Check tire condition and inflation pressure ●●
Check chain and chain guides for wear, force fit and tension ●●
Check screws on pinion and chain sprocket for locking devices and a tight fit ●●
Lubricate chain ●●
Check wheel bearings and jerk damper for play ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURATOR
ENGINE
PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC

ENGLISH
19
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check oil level ●
Check brake fluid level ●
Check brake pads for wear ●
Check lighting system for proper operation ●
Check horn for proper operation ●
Lubricate and adjust actuating cables and nipples ●
Bleed fork legs in regular intervals ●
Remove and clean dust sleeves in regular intervals ●
Clean and lubricate chain as necessary ●●
Check chain tension ●●●
Clean air filter and filter box (depending on the dirt accumulation) ●
Check tire pressure and wear ●
Check coolant level ●
Check fuel lines for leaks ●
Drain float chamber ●
Verify smooth operation of all controls ●
Check brake performance ●●
Treat exposed metal components (except for the braking and exhaust ●
systems) with wax-based anti-corrosion agents
Treat steering lock and light switch with contact spray ●
Check all screws, nuts, and hose clamps for tight fit ●
once a yearfor cross
country use
after every
cleaning
before each
start
PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance ●
Perform complete suspension strut maintenance ●
Perform complete reversing lever maintenance ●
Replace glass-fiber yarn packing of main silencer ●
Clean and lubricate steering-head bearing and sealing elements ●
Clean and adjust the carburetor ●
Treat the electrical contacts and switches with contact spray ●
Change brake fluid ●
every 2 years
or 20000 km
at least
once a year
every 2500 km
or 25 hours