KTM Chassis 690 SMC User manual

OWNER'S MANUAL 2009
690 SMC EU
690 SMC AUS/UK
ART. NO. 3211365en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you
enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design of our motorcycles cannot however be completely excluded.
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 misprints 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)
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 AG
5230 Mattighofen, Austria

CONTENTS 3
CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT NOTES............................................................... 8
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side............................................ 12
View of vehicle, rear right .................................................. 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Key number ..................................................................... 17
Engine number................................................................. 17
Fork part number.............................................................. 18
Shock absorber part number.............................................. 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Light switch ..................................................................... 20
Flasher switch.................................................................. 20
Horn button ..................................................................... 21
Emergency OFF switch...................................................... 21
Electric starter button ....................................................... 22
Ignition/steering lock ........................................................ 22
Combination instrument.................................................... 23
Combination instrument - function buttons ......................... 23
Combination instrument - tachometer................................. 24
Combination instrument - indicator lamps........................... 24
Combination instrument - display....................................... 25
Combination instrument - speedometer............................... 26
Setting kilometers or miles ................................................ 26
Combination instrument - time .......................................... 27
Setting the clock .............................................................. 27
Combination instrument - display ODO ............................... 28
Combination instrument - setting/resetting TRIP 1............... 28
Combination instrument - setting/resetting TRIP 2............... 29
Combination instrument - TRIP F display............................ 30
Combination instrument - coolant temperature indicator ...... 30
Opening filler cap............................................................. 31
Closing filler cap .............................................................. 31
Handrails......................................................................... 32
Seat release ..................................................................... 32
Passenger footrests........................................................... 33
Shift lever........................................................................ 33
Foot brake pedal .............................................................. 34
Side stand ....................................................................... 35
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................... 36
Advice on first use............................................................ 36
Running in the engine....................................................... 37
Loading the vehicle .......................................................... 38
RIDING INSTRUCTIONS ....................................................... 40
Checks before putting into operation .................................. 40
Starting ........................................................................... 41
Starting up ...................................................................... 43
Shifting, riding................................................................. 43
Braking ........................................................................... 46
Stopping, parking ............................................................. 47
Refueling......................................................................... 49

CONTENTS 4
SERVICE SCHEDULE............................................................ 51
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 51
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 53
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 55
Jacking up front of motorcycle ........................................... 55
Taking front from work stand ............................................. 55
Jacking up rear of motorcycle ............................................ 56
Taking the rear from the workstand .................................... 56
Fork/shock absorber.......................................................... 57
Adjusting the compression damping of the fork ................... 57
Adjusting the rebound damping of the fork.......................... 58
Compression damping of the shock absorber ....................... 59
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 59
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 61
Adjusting the rebound damping of the shock absorber.......... 62
Measuring the unloaded rear wheel sag............................... 63
Checking the static sag of the shock absorber ..................... 64
Checking the riding sag of the shock absorber ..................... 65
Adjusting the spring preload of the shock absorber x......... 65
Bleeding the fork legs ....................................................... 66
Cleaning the dust boots of the fork legs .............................. 67
Removing the fork protector............................................... 68
Installing the fork protector ............................................... 69
Checking play of steering head bearing x.......................... 69
Adjusting play of steering head bearing x.......................... 70
Handlebar position ........................................................... 71
Adjusting handlebar position x........................................ 72
Checking chain dirt .......................................................... 73
Cleaning the chain............................................................ 73
Checking the chain tension ............................................... 74
Adjusting the chain tension ............................................... 75
Checking rear sprocket / engine sprocket for wear ................ 77
Checking chain wear......................................................... 78
Adjusting chain guide x.................................................. 79
Checking brake discs ........................................................ 79
Adjusting basic position of handbrake lever......................... 80
Checking the front brake fluid level .................................... 81
Adding front brake fluid x............................................... 81
Checking the front brake linings......................................... 83
Changing the front brake linings x................................... 84
Removing front brake linings x........................................ 86
Installing the front brake linings x................................... 87
Checking free play of foot brake lever ................................. 89
Adjusting basic position of footbrake lever x..................... 89
Checking rear brake fluid level........................................... 90
Adding rear brake fluid x................................................ 91
Checking the rear brake linings.......................................... 93
Changing the rear brake linings x..................................... 93
Removing front wheel x.................................................. 96
Installing the front wheel x.............................................. 97
Removing rear wheel x.................................................... 99
Installing the rear wheel x............................................. 100
Checking the rear hub rubber dampers x........................ 102

CONTENTS 5
Checking the tire condition.............................................. 103
Checking spoke tension................................................... 104
Checking tire air pressure................................................ 105
Removing the seat.......................................................... 106
Mounting the seat .......................................................... 107
Removing the battery x................................................. 107
Installing the battery x.................................................. 108
Recharging the battery x............................................... 109
Changing the main fuse .................................................. 111
Changing the fuses of power consumers............................ 113
Adjusting the engine characteristic................................... 115
Removing the headlight mask with the headlight ............... 117
Installing the headlight mask with the headlight................ 118
Changing the headlight bulb............................................ 119
Changing the parking light bulb ....................................... 120
Changing the flasher bulb ............................................... 121
Checking headlamp setting.............................................. 122
Adjusting the headlight range .......................................... 123
Removing the air filter x............................................... 123
Installing the air filter x................................................ 125
Cooling system ............................................................... 126
Checking the antifreeze and coolant level ......................... 126
Checking the coolant level............................................... 128
Draining the coolant x.................................................. 130
Filling the cooling system x........................................... 131
Adjusting basic position of clutch lever............................. 133
Checking/rectifying the fluid level of the hydraulic clutch ... 133
Checking play in gas Bowden cable .................................. 134
Adjusting the play in the gas Bowden cable x.................. 135
Checking engine oil level................................................. 136
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 136
Draining the engine oil x............................................... 137
Removing the oil filter x................................................ 138
Installing the oil filter x................................................ 140
Cleaning the oil screens x............................................. 140
Filling up with engine oil x............................................ 142
Adding engine oil ........................................................... 143
TROUBLESHOOTING.......................................................... 145
FLASHING CODE ............................................................... 148
CLEANING......................................................................... 153
Cleaning motorcycle ....................................................... 153
CONSERVATION FOR WINTER OPERATION ......................... 155
Conservation for winter operation ..................................... 155
STORAGE .......................................................................... 156
Storage.......................................................................... 156
Putting into operation after storage .................................. 157
TECHNICAL DATA - ENGINE............................................... 158
Capacity- engine oil ........................................................ 159
Capacity - coolant........................................................... 159
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 160
TECHNICAL DATA - CHASSIS ............................................. 163
Lighting equipment ........................................................ 164
Capacity - fuel................................................................ 165
TECHNICAL DATA - FORK................................................... 166
TECHNICAL DATA - SHOCK ABSORBER .............................. 167
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 169
SUBSTANCES.................................................................... 172

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

MEANS OF REPRESENTATION 7
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).
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.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 8
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 ser-
vice schedule 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 work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth-
erwise all warranty claims will be disregarded. 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
Work rules
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
–Switch off the engine and remove the ignition key.
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT NOTES 10
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.
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.

IMPORTANT NOTES 11
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that will possibly lead to light injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information
and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your
own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motor-
cycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 12
3.1View of vehicle, front left side
600637-10

VIEW OF VEHICLE 13
1 Hand brake lever
2 Clutch lever
3 Seat
4 Filler cap
5 Handrail
6 Front brake caliper
7 Shift lever
8 Engine number
9 Side stand
10 Footrest
11 Seat release strap

VIEW OF VEHICLE 14
3.2View of vehicle, rear right
600638-10

VIEW OF VEHICLE 15
1 Ignition/steering lock
2 Light switch, flasher switch, horn button
3 Rear mirror
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Throttle grip
7 Chassis number
8 Brake caliper, rear
9 Passenger footrest
10 Shock absorber, rebound damping
11 Foot brake pedal
12 Level viewer, engine oil

LOCATION OF SERIAL NUMBERS 16
4.1Chassis number
100217-10
The chassis number is stamped on the steering head on the right.
4.2Type label
100218-10
Type label is located on the upper right frame tube below the seat.

LOCATION OF SERIAL NUMBERS 17
4.3Key number
100179-10
The key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
4.4Engine number
600479-10
The engine number is stamped on the left side of the engine under the engine sprocket.

LOCATION OF SERIAL NUMBERS 18
4.5Fork part number
600480-10
The fork part number is stamped on the inner side of the fork stub.
4.6Shock absorber part number
100216-10
The shock absorber part number is on the right of the shock absorber.