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KTM 690 SMC R EU 2021 Owner's Manual

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OWNER'S MANUAL
2021
690 SMC R
Art. no. 3214281en

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Summary of Contents for KTM 690 SMC R EU 2021

  • Page 1 OWNER'S MANUAL 2021 690 SMC R Art. no. 3214281en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.16 Foot brake lever ....... 19 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 6.17 Side stand........19 Symbols used ........5 6.18 Opening the fuel tank filler cap ..19 Formats used........5 6.19 Closing the fuel tank filler cap... 20 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.3 Adjusting the rebound damping of 12 BRAKE SYSTEM ......... 61 the fork........... 42 12.1 Anti-lock braking system (ABS) ..61 10.4 Compression damping of the shock 12.2 Adjusting the basic position of the absorber.......... 42 hand brake lever ......62 10.5 Adjusting the low-speed 12.3...
  • Page 6 TABLE OF CONTENTS 15.4 Draining the coolant ..... 91 INDEX ............. 125 15.5 Filling/bleeding the cooling system ........92 15.6 Changing the coolant ....93 16 TUNING THE ENGINE......... 95 16.1 Changing the riding mode ....95 16.2 Adjusting traction control....95 16.3 Checking the basic position of the shift lever........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle ter- rain (unpaved roads). This vehicle is not suitable for use on race tracks. Info This vehicle is only authorized for operation on public roads in its homologated version.

  • Page 9: Tampering Warning

    An appropriate driver's license is needed to drive the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S04575-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Seat release ( p. 17) Side stand ( p. 19) Shift lever ( p. 18) Compression damping of the shock absorber ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04576-10 Ignition and steering lock ( p. 16) Fork compression adjuster Light switch ( p. 15) Turn signal switch ( p. 15) Horn button ( p. 14) Combination switch ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The Europe type label is located on the right side of the frame. The Australia type label is located on the left side of the frame.

  • Page 15: Engine Number

    SERIAL NUMBERS 5 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10 Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number The shock absorber article number is on the left side of the...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. S03266-10 Hand brake lever The hand break lever is fitted on the right side of the handle- bar.

  • Page 17: Light Switch

    CONTROLS 6 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

  • Page 18: Combination Switch

    Each time the ignition is switched on, all three switch LEDs light up for a function check. If all three LEDs light up during operation, a malfunction has been detected by the engine control unit. Contact an authorized KTM workshop immediately. H02887-01 6.10 Ignition and steering lock The ignition and steering lock is located in front of the seat.

  • Page 19: Overview Of Indicator Lamps

    35) is not active. If the TC indicator lamp and both riding mode lamps light up at same time, a malfunction has been detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if the cornering MTC actively engages. 6.12...

  • Page 20: Grab Handles

    6 CONTROLS 6.13 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. S03277-10 6.14 Passenger foot pegs The passenger foot pegs can be folded up and down. Possible states Passenger foot pegs folded up –...

  • Page 21: Foot Brake Lever

    CONTROLS 6 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.17 Side stand Side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle.

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS Note 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. – Lift cover of fuel tank filler cap and insert the ignition key. –...

  • Page 23: Setting The Combination Instrument

    CONTROLS 6 6.20.3 Setting the combination instrument Condition The motorcycle is stationary. – Press and hold both buttons for 3 – 5 seconds. The Setup menu is displayed. Info In the setup menu, all the indicators can be activated and deactivated. S04366-01 –...

  • Page 24: Setting The Service Interval

    6 CONTROLS – Press the + or ‑ button until the indicator CLK appears in the combination instrument. – Press and hold the ‑ button for 3-5 seconds. The combination instrument switches to the clock setting mode. – Press the ‑ button to select the 24 h display or 12 h display for the clock.

  • Page 25: Distance 2

    CONTROLS 6 Briefly press Next display mode the button Press the but- TR1 is reset to 0.0. for 2–3 seconds. 6.20.8 Distance 2 – Press the + or ‑ button repeatedly until TR2 is shown on the combination instrument. TR2 shows the distance 2 since the last reset, such as between two refueling stops.

  • Page 26: Riding Time 1

    6 CONTROLS 6.20.11 Riding time 1 – Press the + or ‑ button repeatedly until T1 is shown on the combination instrument. T1 shows riding time 1 since the last reset. Briefly press Next display mode the button Briefly press Next display mode the button T1 is reset to 0.0.

  • Page 27: Service Interval Display

    CONTROLS 6 6.20.15 Service interval display – Press the + or ‑ button repeatedly until SER is shown on the combination instrument. SER shows the remaining kilometers until the next service is due. S04394-10 6.20.16 Tachometer – Press the + or ‑ button repeatedly until RPM is shown on the combination instrument.

  • Page 28: Gear Display

    The service display is at the top left of the display. Info If the service display appears, a service is due. Contact an authorized KTM workshop. S04382-01 6.20.20 Distance fuel reserve When the fuel level has reached the reserve mark, TR1 F appears on the display, and the fuel level warning lamp lights up.

  • Page 29: Preparing For Use 7

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 30: Running In The Engine

    7 PREPARING FOR USE – Run the engine in. ( p. 28) Running in the engine – During the run-in phase, do not exceed the specified vehicle speed in the respective gear. Guideline During the first 1,000 km (620 mi) Maximum speed per gear First gear 50 km/h (31.1 mph)
  • Page 31 PREPARING FOR USE 7 Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic. – Check that your luggage is fixed properly at regular intervals. Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 32: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 33: Starting Off

    RIDING INSTRUCTIONS 8 – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the posi- tion After you switch on the ignition, you can hear the fuel pump operating for about two seconds. The function check of the combination instrument is run at the same time.
  • Page 34 8 RIDING INSTRUCTIONS Warning Danger of accidents Adjustments to the vehicle distract attention from traffic activity. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. –...
  • Page 35 – If the oil pressure warning lamp lights up, stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. Contact an authorized KTM workshop. – If the malfunction indicator lamp...

  • Page 36: Quickshifter

    8 RIDING INSTRUCTIONS Guideline Minimum speed before gear change First gear to second gear 30 km/h (18.6 mph) Second gear to third gear 40 km/h (24.9 mph) Third gear to fourth gear 50 km/h (31.1 mph) Fourth gear to fifth gear 55 km/h (34.2 mph) Fifth gear to sixth gear 60 km/h (37.3 mph)

  • Page 37: Motorcycle Traction Control

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 38: Stopping, Parking

    8 RIDING INSTRUCTIONS Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. The ABS effectiveness is only ensured if it is switched on. – Leave the ABS switched on in order to benefit from the protective effect. Warning Danger of accidents The rear wheel can lock due to the engine braking effect.

  • Page 39: Transport

    RIDING INSTRUCTIONS 8 – Apply the brakes on the motorcycle. – Shift the transmission to neutral position. – Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers.
  • Page 40 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. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 41: Service Schedule 9

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 42: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Set the service interval. ( p.

  • Page 43: Tuning The Chassis 10

    TUNING THE CHASSIS 10 10.1 Fork/shock absorber The fork and the shock absorber offer many options for adapting the chassis to the riding style and the payload. Info The recommendations for the suspension setting are shown in table . The table is located on the underside of the front rider's seat.

  • Page 44: Adjusting The Rebound Damping Of The Fork

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 45: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 46: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 47: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10 10.9 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...

  • Page 48: Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle in the area of the footrest bracket. Neither wheel is in contact with the ground.

  • Page 49: Removing The Rear Of The Motorcycle From The Wheel Stand

    SERVICE WORK ON THE CHASSIS 11 11.4 Removing the rear of the motorcycle from the wheel stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Secure the motorcycle against falling over.

  • Page 50: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.7 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 46) – Remove fork protector. ( p. 48) Main work – Push dust boots of both fork legs downward.

  • Page 51: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.9 Installing the fork protector – Position the left fork protector. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 52: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 11.12 Mounting the seat S03282-10 – Hook the seat using holding lugs on to bushings , lower the seat at the rear and push it forward. – Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click.

  • Page 53: Storing The Tool Set

    SERVICE WORK ON THE CHASSIS 11 11.14 Storing the tool set Preparatory work – Open the fuel tank filler cap. ( p. 19) – Remove the seat. ( p. 49) Main work – Store the tool set in the tool set compartment. –...

  • Page 54: Mounting Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.16 Mounting side cover Main work – Position the left side cover using holding lugs on bushings and push towards the rear and, in the rear section, down- ward. – Press the left side cover into the rubber bushing in area –...

  • Page 55: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the headlight mask with the headlight. ( p. 84) – Check the headlight setting. ( p. 86) 11.19 Removing the air filter Preparatory work – Open the fuel tank filler cap. ( p.

  • Page 56: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS Finishing work – Mount the seat. ( p. 50) 11.21 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p.

  • Page 57: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.23 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 58: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 mm (0.2 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...
  • Page 59 SERVICE WORK ON THE CHASSIS 11 – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 60 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 61: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.26 Adjusting chain guide – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 10 Nm (7.4 lbf ft)
  • Page 62 11 SERVICE WORK ON THE CHASSIS Note 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 regulations. Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid.

  • Page 63: Brake System 12

    Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire pressure. –...

  • Page 64: Adjusting The Basic Position Of The Hand Brake Lever

    12 BRAKE SYSTEM Info In the Supermoto ABS mode, the rear wheel may lock and there is a risk of falling. The Supermoto ABS mode is only available in riding mode SPORT. The ABS operates with two independent brake circuits (front and rear brakes).

  • Page 65: Checking The Brake Discs

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 66: Adding The Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 67: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 68: Adjusting The Basic Position Of The Foot Brake Lever

    KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 69: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 70: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 71: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 46) – Lift the motorcycle with the front lifting gear. ( p. 47) Main work – Remove screw and pull wheel speed sensor out of the hole.

  • Page 72: Installing The Front Wheel

    13 WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –...

  • Page 73: Removing The Rear Wheel

    WHEELS, TIRES 13 – Take the motorcycle off the front lifting gear. ( p. 47) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 101999-10 Finishing work –...

  • Page 74: Installing The Rear Wheel

    13 WHEELS, TIRES Info Do not operate the foot brake when the rear wheel is removed. – Remove spacer R04972-10 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease.
  • Page 75 WHEELS, TIRES 13 – Clean and grease the thread of the wheel spindle and nut Long-life grease ( p. 120) – Clean and grease the wheel spindle. Long-life grease ( p. 120) – Mount the damping rubber and rear sprocket carrier in the rear wheel.

  • Page 76: Checking The Rear Hub Damping Rubber Pieces

    Check the chain tension. ( p. 55) 13.6 Checking the tire condition Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.)
  • Page 77 Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened.

  • Page 78: Tubeless Tire System

    The rigid rim design results in a wire spoke wheel that is almost entirely maintenance-free. KTM recommends that the rim seal band be changed after 5 years at the latest, regardless of the actual state of wear. 301978-10 13.8...

  • Page 79: Checking The Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 80: Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 81: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 – Position positive cable with washer – Position negative cable with washer – Mount and tighten the screw. Guideline Screw, battery termi- 4.5 Nm (3.32 lbf ft) S04392-10 – Position positive terminal cover – Position retaining bracket and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 82 14 ELECTRICAL SYSTEM Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 83: Changing The Main Fuse

    ELECTRICAL SYSTEM 14 14.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all electrical power consumers of the vehicle. It is in the housing of the starter relay next to the 12-V battery.

  • Page 84: Changing The Abs Fuses

    14 ELECTRICAL SYSTEM 14.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS.
  • Page 85 ELECTRICAL SYSTEM 14 – Pull off engine electronics control unit from the holder and hang it to the side. Main work – Open fuse box cover S04584-10 – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, clock, engine electronics control unit Fuse 2 - 10 A - ignition, combination instrument, engine electronics control unit...

  • Page 86: Removing The Headlight Mask With The Headlight

    14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 50) 14.7 Removing the headlight mask with the headlight – Cover the fender with a cloth. – Remove screws on both sides. – Tip the headlight mask forward. S03303-10 –...

  • Page 87: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 14 – Position the headlight mask. Info Pay attention to routing of the brake line. – Mount and tighten screws Guideline Screw, headlight 2 Nm (1.5 lbf ft) mask S03303-12 Finishing work – Check the headlight setting. ( p.

  • Page 88: Changing The Position Light Lamp

    14 ELECTRICAL SYSTEM 14.10 Changing the position light lamp Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 89: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 14 The light-dark boundary must be exactly on the lower mark- ing when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...

  • Page 90: Diagnostics Connector

    14 ELECTRICAL SYSTEM 14.15 Diagnostics connector Diagnostics connector is located under the engine electronics control unit. S02147-10...

  • Page 91: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .

  • Page 92: Checking The Coolant Level

    15 COOLING SYSTEM – Place the motorcycle on a horizontal surface using the side stand. – Remove the cover of compensating tank – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 93: Draining The Coolant

    COOLING SYSTEM 15 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 94: Filling/Bleeding The Cooling System

    15 COOLING SYSTEM Condition – The engine is cold. – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw . Take off the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring.

  • Page 95: Changing The Coolant

    COOLING SYSTEM 15 – Remove the cover of the compensating tank. – Add coolant up to the marking – Mount the cover of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...
  • Page 96 15 COOLING SYSTEM – Remove radiator cap – Completely drain the coolant. S03318-11 – Mount and tighten screw with a new seal ring. Guideline Screw plug, water M10x1 15 Nm (11.1 lbf ft) pump drain hole K00402-10 – Stand the motorcycle on a level surface using the side stand. –...

  • Page 97: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 Changing the riding mode Info The desired riding mode can be activated via the MAP button on the combination switch. The setting most recently selected is activated again when restarting. The riding mode can also be changed during the ride. Condition Throttle grip closed.

  • Page 98: Checking The Basic Position Of The Shift Lever

    Info If the TC indicator lamp and both riding mode lamps light up at same time, a malfunction has been detected in the traction control. Contact an authorized KTM workshop. 16.3 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position.

  • Page 99: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...
  • Page 100 17 SERVICE WORK ON THE ENGINE – Thoroughly clean the oil drain plug with magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft) magnet S02209-01 –...
  • Page 101 SERVICE WORK ON THE ENGINE 17 – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) S03324-10 – Position oil screen with the O-rings. –...

  • Page 102: Adding Engine Oil

    118) Info In order to achieve optimal engine oil performance, it is H01066-10 not advisable to mix different engine oils. KTM recommends changing the engine oil where neces- sary. – Mount and tighten filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 103: Cleaning, Care 18

    CLEANING, CARE 18 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 104: Checks And Maintenance Steps For Winter Operation

    18 CLEANING, CARE – Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p.
  • Page 105 CLEANING, CARE 18 – Clean the chain. ( p. 54)

  • Page 106: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 46) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 107: Preparing For Use After Storage

    STORAGE 19 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 108: Troubleshooting

    Join quick release coupling. joined – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Throttle opened while starting When starting, DO NOT open the throt- tle. – Carry out start procedure. ( p.
  • Page 109 – Malfunction in ABS Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 110: Technical Data

    21 TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 692.7 cm³ (42.271 cu in) Stroke 80 mm (3.15 in) Bore 105 mm (4.13 in) Compression ratio 12.7:1 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,600 ± 50 rpm Control OHC, intake with cam levers, exhaust controlled by rocker arm, chain drive...

  • Page 111: Engine Tightening Torques

    TECHNICAL DATA 21 21.2 Engine tightening torques Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Oil nozzle for conrod bearing lubri- 0.8 Nm (0.59 lbf ft) cation Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 112 21 TECHNICAL DATA Screw, stator 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 2701™ Screw, thermostat case 10 Nm (7.4 lbf ft) Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, water pump wheel...

  • Page 113: Capacities

    TECHNICAL DATA 21 Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite ® 243™ Rotor nut M18x1.5 100 Nm (73.8 lbf ft) Nut, engine sprocket M20x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Nut, inner clutch hub M20x1.5 120 Nm (88.5 lbf ft) Loctite ®...

  • Page 114: Electrical System

    21 TECHNICAL DATA front Disc brake with radially mounted four-piston brake caliper, floating brake disc rear Disc brake with single-piston brake caliper, floating Brake discs - diameter front 320 mm (12.6 in) rear 240 mm (9.45 in) Brake discs - wear limit front 4.0 mm (0.157 in) rear...

  • Page 115: Tires

    160/60 ZR 17 M/C (69W) TL Bridgestone Battlax Hypersport S21 F Bridgestone Battlax Hypersport S21 R The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork Fork article number 14.18.8S.12...

  • Page 116: Chassis Tightening Torques

    21 TECHNICAL DATA Sport 10 clicks Full payload 10 clicks Fitted length 391 mm (15.39 in) Spring rate Standard 75 N/mm (428 lb/in) Shock absorber fluid ( p. 119) SAE 2.5 21.9 Chassis tightening torques Screw, chain guard EJOT 1.5 Nm (1.11 lbf ft) Screw, combination instrument EJOT 1 Nm (0.7 lbf ft)
  • Page 117 TECHNICAL DATA 21 Remaining screws on fuel tank 5 Nm (3.7 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw brake line holder on frame M6x12 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw connection, foot brake cylin- 10 Nm (7.4 lbf ft) Screw, ABS control unit 5 Nm (3.7 lbf ft)
  • Page 118 21 TECHNICAL DATA Handle bar end screw 15 Nm (11.1 lbf ft) Nut, manifold on cylinder head Tighten the nuts evenly. The plate should not be bent. Copper paste Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™...
  • Page 119 TECHNICAL DATA 21 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™ Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste Screw, swingarm pivot M12x1.5 80 Nm (59 lbf ft) Nut, angle lever to link fork M14x1.5...

  • Page 120: Substances

    22 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 121 SUBSTANCES 22 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 121) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 122: Auxiliary Substances

    23 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX...

  • Page 123: Standards 24

    STANDARDS 24 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 124: Index Of Special Terms

    25 INDEX OF SPECIAL TERMS Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motorcycle Traction Control Auxiliary function of the motor control that reduces engine torque with spinning rear wheel On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 125: List Of Abbreviations 26

    LIST OF ABBREVIATIONS 26 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 126: List Of Symbols

    ABS warning lamp lights up/flashes yellow – If the ABS warning lamp lights up, the ABS is not active. The ABS warning lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. If the ABS warning lamp flashes slowly, ABS mode Supermoto is active.
  • Page 127 INDEX checking ......55 INDEX Changing the headlight bulb ....85 12-V battery Clutch charging .
  • Page 128 INDEX Fork protector lift stand, raising with ....46 installing ......49 lift stand, removing from .
  • Page 129 INDEX Service ....... 9 Tubeless tire system ..... 76 Service schedule .
  • Page 130 *3214281en* 3214281en 02/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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690 smc r 2021F9703u9

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