Related Manuals for KTM 660 SMC 2004
Summary of Contents for KTM 660 SMC 2004
- Page 1 BEDIENUNGSANLEITUNG2004 660 SMC OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.211.18...
- Page 2 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM-S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS...
- Page 3 If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer.
- Page 4 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The KTM 660 SMC is designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.
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Page 5: Table Of Contents
Chain wear ....... . .25 General information about KTM disc brakes ..26 OPERATION INSTRUMENTS . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. -
Page 7: Indicator Lamps
The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. -
Page 8: Tripmaster Switch
Tripmaster switch – The switch has 3 buttons: MODE, + (plus) and – (minus). MODE The switch can also be mounted on the outer end of the handlebar with a clamp (SP.NO. 583.14.069.350). WARNING O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT Electronic speedometer functions provided by the Tripmaster... - Page 9 The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.
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Page 10: Setting The Clock
SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received. -
Page 11: Activating/Deactivating The Display Modes
Activating/deactivating the display modes It may not be necessary to display all of the display modes (functions) at the same time. It is possible to conceal any information not currently required. By deactivating certain functions, the MODE button will only allow you to select from the activated modes. -
Page 12: Combination Switch
Combination switch The light switch has 3 switch positions. = Light off = Low beam light = High beam light The red short circuit button serves to switch off the engine. Leave the switch pressed, until the engine stops. With the button the horn will sound. -
Page 13: Choke
Choke If you pull the choke button out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. -
Page 14: Handlebar Lock
Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw. CAUTION EVER LEAVE THE KEY INSERTED IN THE LOCK F YOU TURN THE STEERING TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork... -
Page 15: General Tips And Warnings For Starting The Motorcycle
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE LEVER OF VEHICLE jobs (see Customer Service Manual). DRIVERS ALWAYS WEAR A HELMET... -
Page 16: Driving Instructions
If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided. -
Page 17: Starting When The Engine Is Cold
Starting when the engine is cold 1 Open the fuel tap 2 Swing up the side stand 3 Put the gear in neutral 4 Operate the choke 5 Turn on the emergency OFF switch 6 Go to the left of your motorbike. DO NOT open the throttle, and briskly kick the kickstarter ALL THE WAY. -
Page 18: Braking
WARNING CAUTION – A – C VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE THERWISE THE ON WET OR SLIPPERY GROUND THERWISE YOU MIGHT EASILY LOSE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE –... -
Page 19: Periodic Maintenance Schedule 2004
PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC 1. Service after after / every after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km... - Page 20 PERIODIC MAINTENANCE SCHEDULE 2004 660 SMC IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km at least every 2 years or 25 hours once a year or 20000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer...
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Page 21: Maintenance Work On Chassis And Engine
WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER. AT KTM YOUR MOTORCYCLE WILL RECIEVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS. -
Page 22: Check And Adjust Steering Head Bearing
Check and adjust steering head bearing * Check steering head bearing for play periodically. To check this put motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. To adjust, loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise... -
Page 23: Basic Suspension Setup For The Weight Of The Driver
At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing). If your weight exceeds or falls short of this range, you will need to adjust the basic setup for the suspension components accordingly. -
Page 24: Changing The Spring Preloading Of The Shock Absorber
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM Changing the spring preloading of the shock absorber KTM sets the shock absorber for a driver with a weight of approximately 75 kg (165 lb). If the weight of the driver is more or less than 75 kg (165 lb), you should change the spring preloading accordingly. -
Page 25: Checking Rubber Ring On The Wp Rear Shock Absorber
Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. -
Page 26: Correct Chain Tension
Correct chain tension Loosen collar nut , loosen lock nuts , and turn right and left adjusting screws equally far. Tighten lock nuts Before tightening the collar nut, verify that the chain adjusters sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. -
Page 27: General Information About Ktm Disc Brakes
BRAKE FLUID: KTM fills the brake systems with „Motorex Brake Fluid DOT 5.1“ brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 28: Changing The Basic Position Of The Handbrake Lever
Changing the basic position of the handbrake lever The adjusting screw allows you to change the basic position of the hand- brake lever Press the handbrake lever's outer end forward, and, at the same time, turn the adjusting screw. Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. -
Page 29: Replacing The Front Brake Pads
Replacing the front brake pads * Turn the upper bolt approx. 45° in a clockwise direction with a wrench until you see the stopper . Remove the stopper on both bolts, pull out the bolts and demount the retaining spring Carefully press against the brake pads with a screwdriver to move the brake pistons into the basic position. -
Page 30: Changing The Basic Position Of The Brake Pedal
Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set. -
Page 31: Dismounting And Mounting The Front Wheel
Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. To remove the front brake caliper, remove both screws and pull the caliper backwards from the brake disc. -
Page 32: Tires-Air Pressure
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING –... -
Page 33: Check/Set Distance Of The Magnetic Sensor
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. CAUTION NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE “... -
Page 34: Replacing Headlight Lamp/Parking Light Lamp
Replacing headlight lamp/parking light lamp Loosen both rubber bands and tilt headlight mask to the front. Pull the parking light lamp with holder carefully out of the reflector. Pull connector off the headlamp and remove rubber cap . Disengage retaining clip and take bulb out of reflector. When changing the parking- light lamp, simply pull it out of the holder. -
Page 35: Cooling System
Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylinder head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the coolant is also pumped through both aluminum radiators. -
Page 36: Cleaning Of Air Filter
To replace the rear glass fiber yarn pack, drill the rivets open and remove the rear cap NOTE: Always renew the O-rings Glass fiber yarn packs are available in your KTM store. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING AVOID BURNS... -
Page 37: Adjusting The Throttle Cable
Adjusting the throttle cable * The throttle grip should always provide for a backlash of 3-5 mm 3-5 mm (0,12-0,20 in). Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. To adjust the throttle cables, slide back the protection cover . -
Page 38: Checking The Oil Level Of The Hydraulic Clutch
SAE 10 hydraulic oil. Refill oil until oil is discharged from the bore the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with... -
Page 39: Carburator - Adjust Idling
CARBURETOR – Adjust idling * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel and the mixture control screw... -
Page 40: Engine Oil
(see information on the can). 5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. -
Page 41: Oil And Screen Filter Change, Bleeding Of The Oil System
Therefore, we recommend that you have the engine oil changed by your authorized KTM mechanic. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void. -
Page 42: Changing Oil Filter
Introduce the plastic hose into the vent hole , (see page 30) and fill 0.6 liters (0.16 US gallons) of engine oil into the frame’s front tube. Remove plastic hose, start engine, and let it idle (approx. 20 seconds) until oil esca- pes at the hole . -
Page 43: Trouble Shooting
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. - Page 44 Fan defective Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermoswitch (bottom right radiator), contact a KTM dealer High oil consumption Buckling gearing ventilation hose Dislocate i.e. replace non-buckling ventilation hose Engine oil level too high Check engine oil level when the engine is warm;...
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Page 45: Cleaning
CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH... -
Page 46: Technical Specifications - Engine 660 Smc
TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2004 Engine 660 SMC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 654 ccm Bore / Stroke 102 / 80 mm Ratio 11,7 : 1 Fuel unleaded premium gasoline with a least RON 95 (USA = Premium RON 91) -
Page 47: Technical Specifications - Chassis 660 Smc
TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC 2004 660 SMC Frame Central chrome-moly-steel frame Fork White Power 4860 MXMA Wheel travel front/rear 265 / 300 mm (10,6 / 11,8 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing... - Page 48 TIGHTENING TORQUES - CHASSIS 660 SMC 2004 Collar nut front axle M24x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top M10 (10.9) 45 Nm Shock absorber bottom M10 (10.9) 45 Nm Collar screws brake disk front M6 (10.9)
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Page 49: Head Word Index
Braking ........17 General information about KTM disc brakes ..26 Breather plug front fork . - Page 52 ENGLISCH DEUTSCH ITALIENISCH Capacitor Kondensator Condensatore Driving light lamp Fernlichtkontrolle Spia abbagliante Flasher relay Blinkerrelais Relè indicatori Flasher switch Blinkerschalter Deviatore indicatori di direzione Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop Flasher control lamp Blinkerkontrolle spia lampeggiatori Generator Generator Generatore...
- Page 53 ENGLISCH FRANZÖSISCH SPANISCH Capacitor Condensateur Condensador Driving light lamp Temion feu route Lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher switch Bouton de clignotants Interruptor de la luz intermitente Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero Flasher control lamp Temion de clignoteur...
- Page 54 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...
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