Art.Nr. 3.210.
IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.
Introduction We would like to congratulate you on your purchase of a KTM motorcycle. ENGLISH 2 You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation.
Index ENGLISH 4 Page Page SERIAL NUMBER LOCATIONS .............................................5 Replacing front brake pads .............................................28 Chassis number ................................................................5 Check the rear brake fluid level ......................................28 Engine number, engine type.............................................5 Refilling the rear brake fluid reservoir .............................28 OPERATION INSTRUMENTS .......
SERIAL NUMBER LOCATIONS Chassis number Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. Write this number into the relevant area on page 1. ENGLISH The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. 5 OPERATION INSTRUMENTS 1 Clutch lever The clutch lever 1 is located on the left side of the handlebar.
Indicator lamps 1 The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. 2 ENGLISH Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move. The engine must be started in order for the speedometer to be supplied with electricity from the generator.
Tripmaster switch – The switch has 3 buttons: MODE, + (plus) and – (minus). The switch can also be mounted on the outer end of the handlebar with a clamp (SP.NO. 583.14.069.350). WARNING DO + Electronic speedometer functions provided by the Tripmaster switch The display modes on the electronic speedometer will change in the following order. If not, please read the chapter "ACTIVATING AND DEACTIVATING THE DISPLAY MODE." SPEED/ODO display mode SPEED displays the speed in KPH or MPH.
SPEED/CLK (clock) display mode CLK will display time in hours, minutes and seconds. + BUTTON no function – BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK) ENGLISH 8 SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours.
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. SPEED/AVS2 (average speed 2) display mode AVS2 shows the average speed based on the TRP2 and STP2 figures.
Driving motorcycle Standing motorcycle OVERVIEW OF TRIPMASTER FUNCTIONS Display Press + Press – Press MODE Hold MODE for 3 sec ENGLISH X SPEED / ODO no function no function next display mode no function X X SPEED / MAX no function no function next display mode resets MAX to 0 X X SPEED / LAP starts / stops LAP figure LAP remains stops LAP, stores LAP figure, resets LAP to 0 next display mode clears all LAP figures LAP / LAP next figure no function next display mode next displ
Combination switch 2 1 The light switch has 3 switch positions. A = Light off B = Low beam light C = High beam light The red short circuit button 1 serves to switch off the engine. Leave the switch pressed, until the engine stops. With the button 2 the horn will sound. A Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar.
Hot start device 1 ENGLISH 12 If you pull the hot start device 1 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean“ fuel-air mixture of the type needed for hot starts. To deactivate the hot start device, push the hot start button back into its basic position. Shift lever 2,3,4,5 The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration.
Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap A. By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression. 1 A Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation ENGLISH 14 – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read these operating instructions carefully before your first ride. – Enter the chassis, engine and key numbers on page 1. – Familiarize yourself with the operating elements. – Adjust the hand brake lever and foot brake lever to your most comfortable position.
DRIVING INSTRUCTIONS Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.
Starting when the engine is cold 1 2 3 4 5 Open the fuel tap 1 Swing up the side stand Put the gear in neutral Operate the choke 2 Go to the left of your motorbike. DO NOT open the throttle, and briskly kick the kickstarter ALL THE WAY. WARNING – IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PUSH YOUR FOOT UPWARD WITH GREAT VEHEMENCE.
– – – ! – HIGH – – – – WARNING ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE CONTROL OF YOUR MOTORCYCLE. WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE. AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN. A BENT HANDLEBAR MUST ALWAYS BE REPLACED.
PERIODIC MAINTENANCE SCHEDULE 2003 1.
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ENGLISH Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean a
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. CAUTION ! ! CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC.
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 1 of the top triple clamp and turn steering stem bolt 2 clockwise until there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged.
Basic suspension setup for the weight of the driver A To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70 80 kg (wearing full protective clothing).
Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons. Similar to the shock absorber, smaller deviations in your weight can be compensated by adjusting the spring preload. However, if your telescopic fork bumps frequently (hard end stop during compression), you should install harder fork springs to avoid damaging the telescopic fork and frame.
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 A accordingly. This is easily done. NOTE: – Before changing the spring preload note the basic setting, e.g. how many threads are visible above the adjusting ring.
Correct chain tension Loosen collar nut 1, loosen lock nuts 2, and turn right and left adjusting screws 3 equally far. Tighten lock nuts 2. Before tightening the collar nut, verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. Tighten collar nut 1 with 80 Nm.
General information about KTM disc brakes BRAKE CALIPERS: The front brake caliper 1 has 4 brake pistons and is rigidly connected to the fork leg. The rear brake caliper has one brake piston and "floats", which means that it is not rigidly connected to the brake caliper support. The resulting lateral adjustment ensures that the brake pads 2 optimally rest against the brake disk at any time. Secure the screws 3 of the caliper support with Loctite 243 and tighten to 40 Nm.
Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1. In this way, the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. 1 min. 3 mm ! CAUTION ! THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM.
Replacing front brake pads * 3 1 Remove the retainer 1, pull out the bolt 2 and detach the locating spring 3. Carefully press against the brake pads with a screwdriver to move the brake pistons into their basic position. Remove the brake pads 4 from the brake caliper and clean the brake caliper with compressed air. 2 ENGLISH Mount both brake pads and position the locating spring. Push the bolt all the way in and mount the retainer. Make sure the brake pads and the locating spring are properly mounted.
Changing the basic position of the brake pedal * A 1 The basic setting of the foot brake pedal can be changed by turning the end stop roller 1. Using the push rod 2, the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). To keep the stop roller from turning while tightening, insert a hexagon wrench in bore A.
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 1 and pull the caliper backwards from the brake disc. Loosen both clamp screws 2 on the left fork leg. Then loosen the collar nuts 3 before loosening the clamp screws 4 on the right fork leg. Hold the front wheel and withdraw the wheel spindle 5.
Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. Tire size can be found in the technical specifications and in their homologation certificate Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them.
Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly. The TRP1, AVS1, STP1, TRP2 and AVS2 figures will be cleared. To select the unit, select the SPEED/H mode and hold the MODE button for 3 seconds to access the SETUP menu. Press the MODE button 10 times until the KMH/MPH function blinks. Press the + button to move to the options. Press the + button for KMH or the – button for MPH.
Replacing headlight lamp/parking light lamp Loosen both rubber bands 1 and tilt headlight mask to the front. Pull the parking light lamp with holder 2 carefully out of the reflector. Pull connector 3 off the headlamp and remove rubber cap 4. Disengage retaining clip and take bulb out of reflector. When changing the parkinglight lamp, simply pull it out of the holder. 3 4 2 5 33 Insert the new lamp such that the noses 5 engage in the recesses 6 .
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 1 opens and the coolant is also pumped through both aluminum radiators. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down.
Cleaning of air filter * To do this, remove the seat and the air filter cover from the air filter box. Unclap the filter holder 1, swing back and remove air filter plus filter carrier from the filter box. 1 Thoroughly wash the air filter in special cleaning fluid and allow to dry well. Only press out the filter, do not wring out under any circumstances. Oil the dry air filter with a high grade filter oil. Also clean the air filter box. Check carburetor collar for damage and that it is fitted correctly.
Adjusting the throttle cable * The throttle grip should always provide for a backlash of 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. 3-5 mm ENGLISH To adjust the throttle cables, dismount the seat and the tank together with spoilers. Slide back the protection cover 1. Loosen the counter nut 2 and turn the adjusting screw 3 accordingly.
Checking the oil level of the hydraulic clutch 2 1 3 To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws 1 and cover 2 together with the rubber boot 3 . The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell Naturelle HF-E15).Biodegradable hydraulic oil is available from your KTM dealer (50ml).
CARBURETOR – Adjust idling (Keihin-FCRMX 41) * 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 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide.
Engine oil API: SG, SH – 0°C 32°F 10W 40 10W 50 + CAUTION ! ! INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. 15W 40 15W 50 Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. To check, place the motorcycle in an upright position on a level surface. B If the engine is cold, the oil level should be visible at the lower edge A of the inspection glass.
Changing the engine oil * The engine oil change is to be carried out when the engine is still warm. 1 A WARNING AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT NOT BURN YOURSELF. - DO Place the motorbike on a horizontal surface. Remove the plugs (1 and 2), and drain oil into a container. CAUTION ! ! THE SCREW PLUG A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.
Changing oil filter * 2 Replace the oil filter when changing the engine oil. Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. Remove banjo bolt 1 and the three screws. Remove oil filter cover 2 and oil filter. Clean the filter case, oil filter cover and sealing areas. Make sure the oil duct in the oil filter cover is not clogged.
TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
Engine does not rev high Engine will not reach full power Engine stops or splutters in carburetor Engine gets too hot High oil consumption All switched on lamps blown out REMEDY CAUSE Loose carburetor jets Tighten jets Electronical ignition timing faulty Have ignition system checked Fuel supply partically interrupted or carburetor dirty Clean and check fuel system as well as carburetor float is not tight replace the float Air filter very dirty Clean or replace air filter Exhaust system is no
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 ! ! CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC.
45 ENGLISH
TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2003 ENGLISH 46 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio 660 SMC Liquid-cooled single cylinder 4-stroke engine with balancer shaft 653 ccm 102 / 80 mm 11,5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rock
BASIC CARBURATOR SETTING Type Carburator-setting number Main jet Jet needle Idling jet Main air jet Idling air jet Needle position Starting jet Mixture control screw open Slide Performance restrictor Stop pump membrane Hot start device Keihin FCR-MX 41 4138A 165 OBDVT 42 200 100 5.
TECHNICAL SPECIFICATIONS - CHASSIS 660 SMC 2003 ENGLISH Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. Tyres rear Air press.
M24x1,5 M20x1,5 M10 (10.9) M10 (10.9) M6 (10.9) M6 (10.
HEAD WORD INDEX Page Page Serial number locations .........................................................5 Draining the float chamber of the carburetor ......................37 Activating/deactivating the display modes ..........................32 Driving instructions .............................................................15 Adjusting of free travel at the hand brake lever...................27 Electronic speedometer .........................................................
1 ANHANG APPENDIX
660 SMC 2003 ANHANG APPENDIX 2
ANHANG APPENDIX KTM 660 SMC 2003 3
5230 Mattighofen Austria Internet: www.ktm.
