KTM 660 SMC 2005 User manual

OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.45
660 SMC
BEDIENUNGSANLEITUNG2005

ENGLISH
1
IMPORTANT »
Please insert the serial numbers of your motorcycle in the boxes below
Frame number
Engine number
Key number
Stamp of dealer
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above
items, all without previous announcement and without giving reasons. KTM may stop manufacturing cer-
tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or
ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con-
tain extra equipment, which is not applied to standard models.
© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.
COMSUMER INFORMATION FOR AUSTRALIA ONLY
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 inopera-
tive by any person.
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:
– IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.
– IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT
THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

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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 motor-
cycle 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 chas-
sis 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.
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 environmen-
tally 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

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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 interna-
tional 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 serv-
ice 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 manipu-
lations 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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INDEX »
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
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . .6
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . .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, oil filter and screen filter change,
bleeding of the oil system . . . . . . . . . . . . . . . . . . .40
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . .42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
CONSERVATION FOR WINTER OPERATION . . . . . . . . .44
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
RE-INITIATION AFTER TIME OF STORAGE . . . . . . . . .44
TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . .45
TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . .46
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .48
WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . .APPENDIX

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SERIAL NUMBER LOCATIONS »
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 [1] is located on the left side of the handlebar. The adjust-
ing screw [A] is used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
The clutch is hydraulically actuated and adjusts itself automatically.
Hand decompression lever
The hand decompression lever [2] is 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 does-
n’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 [3] is 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).
OPERATION INSTRUMENTS »
1
2
3
A

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OPERATION INSTRUMENTS »
TEST
All of the display segments briefly light up for the display function test.
WS (wheel size)
The display changes and the circumference of the front wheel is briefly dis-
played in millimeters (1882 mm corresponds to a front wheel circumference
of 17" with production tires).
Afterwards the display will return to the previous display mode.
Electronic speedometer
The display in the electronic speedometer is activated as soon as you press
a button on the speedometer or an impulse is received from the wheel sen-
sor. The display lights up when the engine is running.
The display is cleared if no button is pressed for 1 minute or no impulse is
received from the wheel sensor.
The |button is used to change between display modes.
The +and –buttons are used to control various functions.
SPEED display mode / H (service hours)
Only the SPEED / H and SPEED / ODO display modes are activated in the
condition at delivery. SPEED/H is displayed whenever the display is activated
and the front wheel is not turning. It automatically changes to the SPEED/ODO
display mode as soon as the front wheel starts turning.
SPEED displays the speed.
H displays the engine's service hours. The service hour counter starts to count
as soon as you start the engine. The displayed figure cannot be changed.
Service intervals are indicated in service hours for some KTM offroad motor-
cycles, making the service hour counter a very practical function.
SPEED / ODO display mode (odometer)
The SPEED/ODO mode displays the speed and the total distance traveled.
The display automatically changes to the SPEED/H display mode when the
front wheel stops turning.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. changes to the next display mode
The electronic speedometer has a number of display modes (functions) that
you can also activate (reveal) (see: Activating and deactivating display modes).

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OPERATION INSTRUMENTS »
SPEED / LAP (lap time) display mode
You can use the manual stop watch to stop and store up to 10 lap times,
which you can view in the LAP/LAP display mode (see below).
LAP displays the lap times in hours, minutes and seconds.
+button Starts and stops the stop watch, lap time is not
reset to 0
–button Stops the stop watch, stores the lap time and restarts
the stop watch again. The time is reset to 0. A total
of 10 lap times can be stored. If the lap time con-
tinues to run after you press the - button, all 10 mem-
ory locations are occupied.To clear all of the stored
lap times, hold the |button for 3 seconds in the
SPEED/LAP mode.Up to 10 lap times can be stored
in this way.
briefly press |button Changes to the next display mode.If no lap time is
stored or the motorcycle is driving, the LAP/LAP
mode will be skipped.
hold |button 3 secs. Clears all LAP figures
SPEED / CLK (time) display mode
CLK displays the time in hours, minutes and seconds.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. set the clock menu
To set the clock, see „Setting the clock“.
Activating and deactivating display modes
In the display mode SPEED/H, press and hold the |button for 3 seconds to
access the SETUP menu. The active functions will be displayed. The blink-
ing function can be activated by pressing the +button and deactivated by
pressing the –button.
Press and hold the |button 3 seconds to store the settings.
If no button is pressed for 20 seconds, the setting will be stored automati-
cally and the display will return to the SPEED/H mode.
+button activates the blinking display
–button deactivates the blinking display
briefly press |button changes to the next display without changing any
settings
hold |button 3 secs. starts the SETUP
stores the settings and changes to the SPEED/H
mode
The following display modes can be activated:
TR1 tripmaster 1
TR2 tripmaster 2
A1 average speed 1
A2 average speed 2
S1 stop watch 1
S2 stop watch 2
CLK clock
LAP lap time
MAX maximum speed
KMH/MPH display in kilometers or miles (see: Kilometers or miles)
If you have activated all of the display modes, they will be displayed in the
following order:
SPEED/H, SPEED/CLK, SPEED/LAP, LAP/LAP, SPEED/MAX, SPEED/ODO,
SPEED/TR1, SPEED/TR2, SPEED/A1, SPEED/A2, SPEED/S1, SPEED/S2

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OPERATION INSTRUMENTS »
LAP / LAP display mode (to view lap times)
The LAP/LAP display mode will only be shown if lap times have been stored
and the front wheel has stopped. It will display the lap number and the
stopped lap time in hours, minutes and seconds. Press the +button to access
the next lap time.
To clear all of the stored lap times, hold the |button for 3 seconds in the
SPEED/LAP mode.
+button changes to the next lap time
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. changes to the next display mode
SPEED / MAX display mode (maximum speed)
MAX displays the maximum speed traveled and is always active.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. clears the MAX figure
SPEED / TR1 display mode (tripmaster 1)
The TR1 tripmaster is always active and counts to 999.9. It is used to meas-
ure the length of a trip or the distance between 2 refueling stops.
TR1 is linked to A1 (average speed 1). The calculation of these figures is acti-
vated 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 TR1, A1 and S1 figures are automatically cleared after passing 999.9.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. clears the TR1, S1, A1 figures
SPEED / TR2 display mode (tripmaster 2)
The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the
displayed figure can be changed using the +and –buttons. This is a very use-
ful function for trips taken according to a roadbook.
+button increases the TR2 figure
–button decreases the TR2 figure
briefly press |button changes to the next display mode
hold |button 3 secs. clears the TR2 figure
SPEED / A1 display mode (average speed 1)
A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop
watch 1) 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
briefly press |button changes to the next display mode
hold |button 3 secs. clears the TR1, S1, A1 figures

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OPERATION INSTRUMENTS »
Kilometers or miles
The unit (kilometers or miles) can also be changed. The ODO figure will be
retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures
will be cleared.
To select the unit, select the SPEED/H mode and hold the |button for 3 sec-
onds to access the SETUP menu. Press the |button until the KMH/MPH
function blinks. Press the +button briefly to move to the options. Press the
+button for KMH or the –button for MPH.
To set, briefly press the |button 1 x and hold for 3 seconds until the dis-
play returns to the SPEED/H mode.
If no button is pressed for 20 seconds, the setting will be stored automati-
cally and the display will return to the SPEED/H mode.
+button to access the menu
to activate the KMH display
–button to activate the MPH display
briefly press |button changes to the next mode
changes from the menu to the SETUP menu
hold |button 3 secs. stores and closes the SETUP menu
SPEED / A2 display mode (average speed 2)
A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop
watch 2) figures.
The displayed figure can deviate from the actual average speed if the TR2
figure was changed manually or if S2 was not stopped after the trip.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. changes to the next display mode
SPEED / S1 display mode (stop watch 1)
S1 shows the traveling time based on TR1 and continues to run whenever it
receives impulses from the wheel sensor. The calculation of this figure is acti-
vated by the first impulse received from the wheel sensor and stops 3 sec-
onds after the last impulse is received.
+button no function
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. clears the TR1, S1, A1 figures
SPEED / S2 display mode (stop watch 2)
S2 is a manual stop watch. Start the stop watch by pressing the +button,
press again to hold. Press again to continue timing.
Press the |button to change to the next mode. The S2 display will blink in
the other modes if S2 continues to run in the background. To stop S2, return
to the SPEED/S2 mode and press the +button.
+button starts and stops the stop watch
–button no function
briefly press |button changes to the next display mode
hold |button 3 secs. clears the S2 figure