KTM Chassis 690 SMC User manual

OWNER'S MANUAL 2008
690SMCUSA
ART. NO. 3211305en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( S. 22) Dealer's stamp
Engine number ( S. 23)
Key number ( S. 23)
The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small
deviations arising from further development in design and construction.
All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that
lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 3
CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT NOTES............................................................... 8
Overview of warning labels................................................. 10
VIEW OF VEHICLE................................................................ 18
View of vehicle, front left side............................................ 18
View of vehicle, rear right side ........................................... 20
LOCATION OF SERIAL NUMBERS ......................................... 22
Chassis number................................................................ 22
Type label........................................................................ 22
Key number ..................................................................... 23
Engine number................................................................. 23
Fork part number.............................................................. 24
Shock absorber part number.............................................. 24
OPERATING ELEMENTS....................................................... 25
Clutch lever ..................................................................... 25
Hand brake lever .............................................................. 25
Light switch ..................................................................... 26
Light switch ..................................................................... 26
Headlight flasher switch.................................................... 27
Flasher switch.................................................................. 27
Flasher switch.................................................................. 28
Horn button ..................................................................... 28
Horn button ..................................................................... 29
Emergency OFF switch...................................................... 29
Electric starter button ....................................................... 30
Ignition/steering lock ........................................................ 30
Combination instrument.................................................... 31
Combination instrument - function buttons ......................... 31
Combination instrument - tachometer................................. 32
Combination instrument - control lamps ............................. 32
Combination instrument - Display ...................................... 33
Combination instrument - speed display ............................. 34
Setting kilometers or miles ................................................ 34
Combination instrument - time .......................................... 35
Setting the clock .............................................................. 35
Combination instrument -ODO display ............................... 36
Combination instrument - setting/resettingTRIP1 display.... 36
Combination instrument - setting/resettingTRIP2 display.... 37
Combination instrument -TRIPF display ............................ 38
Combination instrument - coolant temperature indicator ...... 38
Opening filler cap............................................................. 39
Closing filler cap .............................................................. 39
Handrails......................................................................... 40
Seat release ..................................................................... 40
Passenger footrests........................................................... 41
Shift lever........................................................................ 41
Foot brake pedal .............................................................. 42
Side stand ....................................................................... 43
GENERAL TIPS ON PUTTING INTO OPERATION .................... 44
Advice on first use............................................................ 44
Running in the engine....................................................... 45
Loading the vehicle .......................................................... 46
RIDING INSTRUCTIONS ....................................................... 48
Checks before putting into operation .................................. 48
Starting ........................................................................... 49
Starting up ...................................................................... 51
Shifting, riding................................................................. 51
Braking ........................................................................... 54

CONTENTS 4
Stopping, parking ............................................................. 55
Refueling......................................................................... 57
GREASING AND SERVICE TABLE.......................................... 59
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 59
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 61
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 63
Jacking up front of motorcycle ........................................... 63
Taking front from work stand ............................................. 63
Jacking up rear of motorcycle ............................................ 64
Take the rear from the work stand. ..................................... 64
Fork/shock absorber.......................................................... 65
Adjusting compression damping of fork .............................. 65
Adjusting rebound damping of fork..................................... 66
Compression damping of shock absorber............................. 67
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 67
Adjusting high-speed compression damping of the shock
absorber .......................................................................... 68
Adjusting rebound damping of the shock absorber ............... 70
Bleeding fork legs............................................................. 70
Cleaning dust boots of fork legs ......................................... 71
Removing the fork protector............................................... 72
Installing the fork protector ............................................... 73
Checking play of steering head bearingx.......................... 73
Adjusting play of steering head bearingx.......................... 74
Handlebar position ........................................................... 75
Adjusting handlebar positionx........................................ 76
Adjusting the handlebar anglex....................................... 77
Checking chain dirt .......................................................... 77
Cleaning the chain............................................................ 77
Checking the chain tension ............................................... 78
Adjusting chain tension..................................................... 79
Checking rear sprocket / engine sprocket for wear ................ 81
Checking chain wear......................................................... 82
Adjusting chain guidex.................................................. 83
Checking brake discs ........................................................ 83
Adjusting basic position of handbrake lever......................... 84
Checking front brake fluid level.......................................... 85
Adding brake fluid for front brakex.................................. 85
Brake linings.................................................................... 87
Checking the front brake linings......................................... 88
Changing the front brake liningsx.................................... 88
Removing front brake liningsx........................................ 90
Mounting front brake liningsx......................................... 91
Checking free play of foot brake lever ................................. 93
Adjusting basic position of foot brake pedalx................... 93
Checking rear brake fluid level........................................... 94
Topping up brake fluid of rear brakex.............................. 95
Checking the rear brake linings.......................................... 97
Changing rear brake liningsx.......................................... 97
Removing front wheelx................................................ 100
Installing the front wheelx............................................ 102
Removing rear wheelx.................................................. 103
Installing the rear wheelx............................................. 104
Checking the rear hub rubber dampersx........................ 106

CONTENTS 5
Tire condition checking................................................... 107
Checking spoke tension................................................... 108
Checking tire air pressure................................................ 109
Removing the seat.......................................................... 110
Mounting the seat .......................................................... 110
Removing the batteryx................................................. 111
Installing the batteryx.................................................. 112
Recharging the batteryx............................................... 112
Changing the main fuse .................................................. 114
Changing fuses of individual power consumers .................. 116
Adjusting the engine characteristic................................... 118
Removing headlight mask with headlight .......................... 120
Refitting the headlight mask with the headlight................. 121
Changing the headlight bulb............................................ 122
Changing the parking light bulb ....................................... 123
Changing the rear lamp................................................... 124
Changing the flasher bulb ............................................... 125
Checking headlamp setting.............................................. 126
Adjusting the headlight range .......................................... 126
Removing the air filterx............................................... 127
Installing the air filterx................................................ 128
Cooling system ............................................................... 129
Checking the antifreeze and coolant level ......................... 130
Checking the coolant level............................................... 132
Draining coolantx........................................................ 134
Filling the cooling systemx........................................... 135
Adjusting basic position of clutch lever............................. 137
Checking/correcting fluid level of hydraulic clutch ............. 137
Checking play in gas Bowden cable .................................. 138
Adjusting play in gas Bowden cablex............................. 139
Checking engine oil level................................................. 140
Changing engine oil and oil filter, cleaning oil
screensx..................................................................... 140
Draining engine oilx.................................................... 141
Removing the oil filterx................................................ 142
Mounting oil filterx...................................................... 144
Cleaning oil screensx................................................... 144
Filling up with engine oilx............................................ 146
Topping up engine oil ..................................................... 147
TROUBLESHOOTING.......................................................... 148
FLASHING CODE ............................................................... 151
CLEANING......................................................................... 154
Cleaning motorcycle ....................................................... 154
CONSERVATION FOR WINTER OPERATION ......................... 156
Conservation for winter operation ..................................... 156
STORAGE .......................................................................... 157
Storage.......................................................................... 157
Putting into operation after storage .................................. 158
TECHNICAL DATA - ENGINE............................................... 159
Capacity - engine oil ....................................................... 160
Capacity - coolant........................................................... 160
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 161
TECHNICAL DATA - CHASSIS ............................................. 164
Lighting equipment ........................................................ 165
Capacity - fuel................................................................ 166
TECHNICAL DATA / FORK................................................... 167
TECHNICAL DATA - SHOCK ABSORBER .............................. 168
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 170

CONTENTS 6
SUBSTANCES.................................................................... 173
AUXILIARY SUBSTANCES................................................... 176
STANDARDS...................................................................... 178
INDEX ............................................................................... 179

MEANS OF REPRESENTATION 7
1MEANS OF REPRESENTAT ION
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally
by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Eigenname Indicates a proprietary name.
Name®Identifies a protected name.
Marke™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 8
2IMPORTANT NOTES
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work described in the greasing and service table must be carried out exclusively in an authorized KTM workshop and
confirmed in the service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting
from manipulation and/or other changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES 9
Spare parts, accessories
In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
The currentKTMPowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damage Danger of damage by the vehicle running away or falling over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.
–Do not place the vehicle where there are flammable or explosive substances.
–Switch off the engine and remove the ignition key.
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that
such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 10
2.1Overview of warning labels
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IMPORTANT NOTES 11
1 Type label, Canada
2 Type label, USA
3 Information, emission control
4 Information, noise emission
5 Information, suspension setting
6 Information, chain tension
7 Information, fuel evaporation system
8 Information, putting into operation
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Type label, Canada

IMPORTANT NOTES 12
100340-01
Type label, USA
100339-01
Information, emission control

IMPORTANT NOTES 13
100342-01
Information, noise emission
100344-01
Information, suspension setting

IMPORTANT NOTES 14
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Information, chain tension
100336-01
Information, fuel evaporation system
700210-01
Information, putting into operation

IMPORTANT NOTES 15
notes/warnings
Be sure to pay attention to the notes and warnings given here.
Info
Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If these are removed,
you or other persons may not recognize potential danger and therefore be liable to injury.
Grades of risks
Danger
Danger of leading to immediate, certain, serious, permanent injuries or death.
Warning
Danger of probable, serious, permanent injuries or death.
Caution
Danger of possible light injury.
Note
Danger of considerable engine or material damage.
Warning
Danger of environmental damage.
Owner's manual
–Be sure to read this owner's manual carefully and completely before taking your first ride. It contains a lot of information and tips to
help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and
how you can protect yourself from injury. This owner's manual also contains important information about servicing the motorcycle.

IMPORTANT NOTES 16
–The owner's manual is an important component of the motorcycle and should be passed on to the new owner if the bike is sold.
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-
tion about motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telephone: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Kanada
Telephone: [phone] x 39
www.ktmcanada.com
Tampering warning
Tampering with noise control system prohibited.Federal law prohibits the following acts or causing thereof:
1 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 pur-
chaser or while it is in use, or

IMPORTANT NOTES 17
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
1 Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
Warning, operating noise
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the
owner may become subject to penalties under state and local ordinances.
Consumer rights
Limited warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telephone: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Kanada
Telephone: [phone] x 39
www.ktmcanada.com
Your rights may vary, please refer to the applicable state laws.

VIEW OF VEHICLE 18
3VIEW OF VEHICLE
3.1
View of vehicle, front left side
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