KTM 690 SMC R Manual

SETUP INSTRUCTIONS 2017
690 SMC R
Art. no. 3213599en

INTRODUCTION 1
*3213599en*
3213599en
10/2016
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It
is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
690 SMC R EU (F9703Q9)

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
S01530-10
–Remove the straps and box.
S01534-10
–Remove the adhesive tape in the upper area of the motorcycle.
S01535-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking, leave the other films
on the vehicle until you have finished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the separate enclosure for
completeness.
–Check the vehicle for transport damage.
S01533-10
–Remove the screws and handlebar clamps.
S00795-10
–Remove screw 1of the right hand guard.
S00796-10
–Position the controls on the right half of the handlebar.
Info
The figure shows how to route the cable and lines.
–Mount the screws.

2 SETUP 4
S00797-10
–Position the handlebar.
–Position the handlebar clamps. Mount the four screws and tighten evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
The markings Aof the handlebar scale are located centrally between the han-
dlebar clamps.
Markings Bface backwards.
S00798-10
–Position the controls on the left half of the handlebar.
–Mount the screws.
S00799-10
–Position all controls in their exact positions on the handlebar.
–Tighten screws 2and 3.
Guideline
Screw, throttle grip M5 3.5 Nm
(2.58 lbf ft)
Screw, brake assembly M6 5 Nm (3.7 lbf ft)
–Check the throttle grip for smooth operation.
–Mount and tighten the screw of the right hand guard.
–Tighten screws 4and 5.
Guideline
Screw, combination switch, left M5 3.5 Nm
(2.58 lbf ft)
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)
K00062-01
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
100308-01
–Mount the footrests with springs and pins. Secure the pins using washers and cot-
ter pins.
Pliers for footrest spring (58429083000)
–Remove the protective plastic.
–Carefully loosen and remove the tension belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the palette.

2 SETUP 5
S00801-10
–Recharge the battery. ( p. 7)
–Install the battery. ( p. 8)
–Plug in connector 6on the starter relay.
S00802-10
–Remove the rear fairing. ( p. 10)
–Four markings 7are found on the underside of the rear fairing. At these location,
drill holes to the specified diameter in three stages.
Guideline
Hole diameter for grab handles 14.5 mm (0.571 in)
S00803-10
–Remove screws 8.
–Fit the rear fairing. ( p. 10)
201901-10
–Mount the reflector.
Operation as a 2-seater
–Mount rear footrest bracket. ( p. 11)
Operation as a 1-seater (only if requested by customer)
Warning
Forfeiture of homologation and insurance cover The vehicle is
homologated as 2-seater. If the heel protector is fitted instead of the
footrest bracket, the vehicle no longer conforms to the homologation and
must not be operated in this form without alterations to the registration
papers.
–Set up and operate the vehicle as a 2-seater or have changes made
to the registration papers.
–Mount heel protector. ( p. 11)
–Refuel. ( p. 11)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.
–Set the kilometers or miles. ( p. 13)

3 WORK 6
3.1 Removing the seat
101977-10
–Pull on strap 1and raise the rear of the seat at the same time.
–Pull back the seat and lift it off.
3.2 Mounting the seat
101988-10
–Hook slot 1of the seat onto screw 2, press the rear downward and at the same time push it forward.
–Push locking pin 3into lock housing 4and push the back of the seat down until the locking pin locks in place with an audible
click.
–Check, finally, that the seat is correctly mounted.
3.3 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Preparatory work
–Switch off the ignition by turning the ignition key to position OFF .
–Remove the seat. ( p. 6)
B01974-10
Main work
–Remove battery cover 1.
–Pull engine electronics control unit 2off of the holder and set it to one side.

3 WORK 7
S00622-10
–Disconnect negative cable 3from the battery.
–Take off positive terminal cover 4.
S00620-10
–Disconnect ABS connection cable 5and positive cable 6from the battery.
S00621-10
–Remove screws 7.
–Pull retaining bracket 8of the battery forward and remove it.
–Lift the battery up and out.
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle will therefore no longer be roadworthy.
3.4 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

3 WORK 8
Info
Even when there is no load on the battery, it still loses power steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
Preparatory work
–Switch off the ignition by turning the ignition key to position OFF .
–Remove the seat. ( p. 6)
–Remove the battery. ( p. 6)
S01013-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.
–Switch off the battery charger after charging and disconnect from the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Install the battery. ( p. 8)
–Mount the seat. ( p. 6)
–Set the clock. ( p. 12)
3.5 Installing the battery
S00621-11
Main work
–Insert the battery into the battery compartment with the terminals facing rearward.
Battery (YTZ10S)
–Position retaining bracket 1and mount and tighten screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
S00623-10
–Position washer 3, positive cable 4, and ABS connection cable 5.
–Mount and tighten screw 6.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)

3 WORK 9
S00622-11
–Position positive terminal cover 7.
–Position washer 8and negative cable 9, and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
S00624-10
–Position the engine electronics control unit bk.
–Mount battery cover bl.
Finishing work
–Mount the seat. ( p. 6)
–Set the clock. ( p. 12)
3.6 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
101975-10
–Lift cover 1of filler cap and insert the ignition key.
–Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
The filler cap has a fuel tank breather.

3 WORK 10
3.7 Closing filler cap
101976-01
–Put the filler cap back on and turn the ignition key 90° clockwise.
–Remove the ignition key and fold down the cover.
3.8 Removing rear fairing
Preparatory work
–Remove the seat. ( p. 6)
S00811-10
Main work
–Remove screws 1.
100314-10
–Remove screws 2.
–Open the filler cap. ( p. 9)
–Take off the rear fairing.
–Close the filler cap. ( p. 10)
3.9 Fitting the rear fairing
S00806-10
–Position the license plate holder and cable harness.
–Open the filler cap. ( p. 9)
–Position the rear fairing and grab handles 1as shown in the figure. Fit and
slightly tighten the screws of the grab handles.
–Close the filler cap. ( p. 10)
S00811-11
–Mount and tighten the rear fairing fixing screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

3 WORK 11
S01536-10
–Mount and tighten screws 3.
–Tighten the screws of the grab handles.
Guideline
Screw, grab handle M8 10 Nm (7.4 lbf ft)
–Mount the seat. ( p. 6)
3.10 Mounting rear footrest bracket
Info
The operations are the same for the left and right sides.
S00784-10
–Position the footrest bracket 1. Mount and tighten screws 2.
Guideline
Screw, rear footrest bracket M8x16 25 Nm
(18.4 lbf ft)
3.11 Mounting heel protector
Info
The operations are the same for the left and right sides.
S00808-10
Warning
Forfeiture of homologation and insurance cover The vehicle is homologated
as 2-seater. If the heel protector is fitted instead of the footrest bracket, the
vehicle no longer conforms to the homologation and must not be operated in
this form without alterations to the registration papers.
–Set up and operate the vehicle as a 2-seater or have changes made to
the registration papers.
–Position the heel protector 1. Mount and tighten screws 2.
Guideline
Screw, heel protector M8x12 5 Nm
(3.7 lbf ft)
Loctite®243™
3.12 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

3 WORK 12
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the
fuel system.
–Refuel only with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
400405-10
–Switch off the engine.
–Open the filler cap. ( p. 9)
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement A20 mm (0.79 in)
Total fuel tank
capacity, approx.
12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 16)
–Close the filler cap. ( p. 10)
401429-10
–Press the SET button 2for two seconds.
The fuel level warning lamp 1switches off. TRIP F is set to 0.0 and the dis-
play returns to the previous display mode.
Info
If you do not press the SET button 2, the reset takes place automatically
after approx. three minutes.
3.13 Setting the clock
Condition
The motorcycle is stationary.
401444-01
–Switch on the ignition by turning the ignition key to position ON .
–Press the MODE button repeatedly until the ODO mode is active.
–Keep the MODE button and the SET button pressed simultaneously.
The time display begins to flash.
–Press the MODE button to set the hour.
–Press the SET button to set the minute.
–Keep the MODE button and the SET button pressed simultaneously.
The time is set.

3 WORK 13
3.14 Setting the kilometers or miles
Info
If the unit is changed, the value is retained and converted accordingly.
Make the setting according to the country.
Condition
The motorcycle is stationary.
401444-01
–Switch on the ignition by turning the ignition key to position ON .
–Press the MODE button repeatedly until the ODO display mode is active.
–Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.

4 TECHNICAL DATA 14
4.1 Chassis tightening torques
Screw, chain guard EJOT 2 Nm (1.5 lbf ft) –
Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) –
Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) –
Screw, side cover on spoiler EJOT 1 Nm (0.7 lbf ft) –
Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) –
Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) –
Fitting, side stand switch M4 2 Nm (1.5 lbf ft) –
Spoke nipple, front wheel M4.5 4 Nm (3 lbf ft) –
Spoke nipple, rear wheel M4.5 4 Nm (3 lbf ft) –
Bolt, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite®243™
Remaining nuts, chassis M5 4 Nm (3 lbf ft) –
Remaining screws, chassis M5 4 Nm (3 lbf ft) –
Screw, brake line holder on swingarm M5 4 Nm (3 lbf ft) –
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft) –
Screw, combination switch, left M5 3.5 Nm (2.58 lbf ft) –
Screw, electrical holder M5 3 Nm (2.2 lbf ft) –
Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) Loctite®243™
Screw, fuel hose clamp on fuel tank M5 5 Nm (3.7 lbf ft) –
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 4 Nm (3 lbf ft) –
Screw, fuel tank closure flange M5 2.5 Nm (1.84 lbf ft) –
Screw, headlight mask M5 5 Nm (3.7 lbf ft) –
Screw, pressure regulator M5 4 Nm (3 lbf ft) –
Screw, throttle grip M5 3.5 Nm (2.58 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws on fuel tank M6 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft) –
Screw, ABS control unit M6 5 Nm (3.7 lbf ft) –
Screw, air filter box top M6 2 Nm (1.5 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, brake assembly M6 5 Nm (3.7 lbf ft) –
Screw, brake fluid reservoir of rear
brake
M6 5 Nm (3.7 lbf ft) –
Screw, chain guard M6 2 Nm (1.5 lbf ft) Loctite®243™
Screw, chain guide M6 8 Nm (5.9 lbf ft) –
Screw, chain sliding guard M6 8 Nm (5.9 lbf ft) Loctite®243™
Screw, clutch assembly M6 5 Nm (3.7 lbf ft) –
Screw, fan hood M6 3 Nm (2.2 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, lower radiator bracket M6 8 Nm (5.9 lbf ft) –
Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, radiator bleeding M6 8 Nm (5.9 lbf ft) –
Screw, radiator guard M6 8 Nm (5.9 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, seat lock M6 5 Nm (3.7 lbf ft) –
Screw, side cover M6 5 Nm (3.7 lbf ft) –
Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator M6 8 Nm (5.9 lbf ft) –

4 TECHNICAL DATA 15
Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701™
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) –
Screw, fuel tank, bottom M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, fuel tank, top M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, grab handle M8 10 Nm (7.4 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, heel protector M8x12 5 Nm (3.7 lbf ft) Loctite®243™
Screw, license plate holder, top M8 20 Nm (14.8 lbf ft) –
Screw, main silencer clamp M8 12 Nm (8.9 lbf ft) Copper paste
Screw, main silencer holder M8 25 Nm (18.4 lbf ft) –
Screw, main silencer holder on fuel
tank
M8 25 Nm (18.4 lbf ft) –
Screw, rear footrest bracket M8x16 25 Nm (18.4 lbf ft) –
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, spring holder on side stand
bracket
M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite®243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite®243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) –
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Screw, swingarm pivot M12 80 Nm (59 lbf ft) –
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) –
Screw, radiator temperature sensor M18 20 Nm (14.8 lbf ft) –
Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite®243™
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) –

5 SUBSTANCES 16
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

*3213599en*
3213599en
10/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM