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KTM 660 SMC 2003, Owner'S Manual, Page: 1 / 55

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KTM 660 SMC 2003 Owner'S Manual Download Page 1

OWNER’S MANUAL 

MANUALE D’USO

MANUEL D’UTILISA

TION

MANUAL DE INSTRUCCIONES

2003

BEDIENUNGSANLEITUNG 

Art.Nr

. 3.210.54  9/2002

660

SMC  

Summary of Contents for 660 SMC 2003

Page 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art Nr 3 210 54 9 2002 660 SMC...

Page 2: ...emoval or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise...

Page 3: ...formed 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...

Page 4: ...ed in the owner s manual or those of an equal quality must be used in accordance with the maintenance schedule The warranty or guarantee shall become void for damage and consequential damage caused by...

Page 5: ...the front brake fluid reservoir 27 Check the front brake pads 27 Page Replacing front brake pads 28 Check the rear brake fluid level 28 Refilling the rear brake fluid reservoir 28 Changing the basic p...

Page 6: ...decompression lever 2 is only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the next attempt This is due to the fact that...

Page 7: ...meters If the front wheel does not turn the display will automatically change to the SPEED H mode If the front wheel turns the display will automatically change to the SPEED ODO mode SPEED H hours dis...

Page 8: ...ange to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stop...

Page 9: ...the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TRP1 AVS1 and STP1 fig...

Page 10: ...impulse received from the wheel sensor and stops 3 seconds after the last impulse is received The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 w...

Page 11: ...d MODE for 3 sec no function no function stops LAP stores LAP figure resets LAP to 0 no function no function no function no function no function no function decreases TRP2 figure no function no functi...

Page 12: ...without kinks Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON When using the motorcycle the rotating handle must be set to the ON position Now fuel may flow...

Page 13: ...e illustration Neutral position is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled Foot brake pedal The foot...

Page 14: ...the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw...

Page 15: ...e limits The engine speed of 4800 r p m must not be exceeded during the first 1000 kilometers 620 miles During this break in time you should ride your motorcycle in different conditions roads easy off...

Page 16: ...pressure deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way...

Page 17: ...ition and if you let go of the clutch lever the engine will stop Starting when the engine is warm or hot 1 Open the fuel tap 1 2 Swing up the side stand 3 Put the gear in neutral 4 Push the hot start...

Page 18: ...SPECT NEED BE TAKEN THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVER REV...

Page 19: ...ght turn indicators tell tale lamps horn emergency off switch Make sure all screws and nuts are tight Check brake fluid level lining thickness and brake discs Check brake lines for damage and leaks Ch...

Page 20: ...and lubricate chain as necessary Check chain tension Clean air filter and filter box depending on the dirt accumulation Check tire pressure and wear Check coolant level Check fuel lines for leaks Dra...

Page 21: ...LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED REMOVE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC ORDERLY UNDER NO CIRCUM...

Page 22: ...ather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 3 a few turns in order to relieve excess pressure from the inside of the fork To do this place the mo...

Page 23: ...ain to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 580 mm Static sag 20...

Page 24: ...5 and 5 mm see spare parts catalog NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in various heights...

Page 25: ...RBER WARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE T...

Page 26: ...e brushes or solvents After letting the chain dry you can use a special X ring chain spray Motorex Chainlube Racing WARNING NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWIS...

Page 27: ...kes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum either the brake system has a l...

Page 28: ...brake fluid falls to the middle of the inspection glass new brake fluid has to be added Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the...

Page 29: ...ing upright WARNING IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY...

Page 30: ...ED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFE...

Page 31: ...M DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT I...

Page 32: ...DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESU...

Page 33: ...The blinking digits can be changed using the and buttons Press the MODE button to move to the next digit If no button is pressed for 20 seconds the settings will be stored automatically and the displa...

Page 34: ...that it remains free from fat Engage retaining clip mount rubber cap and connector If the parking light lamp is to be replaced simply insert it in the holder Reinsert the parking light lamp together...

Page 35: ...RESSURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS IN CASE YOU GET BURNT HOLD THE AFFECTED PART OF...

Page 36: ...THE ENGINE AND LEAD TO INCREASED WEAR HAVING MOUNTED THE AIR FILTER CHECK IT FOR CORRECT FIT THE FRONT END A MUST ABOUT THE AIR FILTER BOX OTHERWISE DUST AND DIRT MAY GET INTO THE ENGINE AND LEAD TO...

Page 37: ...on can be heard Now the decompression lever must be operated 10 mm until resistance is felt the exhaust valves begin to open To adjust move back the protective cover 4 loosen the counter nut 5 and cor...

Page 38: ...dure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is avai...

Page 39: ...ed idling nozzle may be the cause If a the mixture control screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine...

Page 40: ...RADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE DO NOT OVERFILL THE ENGINE CASE DO NOT UNDERFILL THE ENGINE CASE Oil circuit The oil pump 1 pumps the engine oil past the by pass valve 2 through t...

Page 41: ...filter cover for leakage Check the engine oil level and correct if necessary Changing and bleeding the microfilter Replace the microfilter while changing the engine oil To do so remove hexagon screws...

Page 42: ...e 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 Place the new oil filter...

Page 43: ...riods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off wh...

Page 44: ...l too thin viscosity Capacitor or voltage regulator faulty REMEDY Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor replace the float Clean or replace air fil...

Page 45: ...the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be clos...

Page 46: ...ENGLISH 45...

Page 47: ...1 6 liters 0 42 US gallons Primary ratio straight geared spur wheels 31 79 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio 1st 14 35 2nd 15 24 3rd 18 21 4th 20...

Page 48: ...g number 4138A Main jet 165 Jet needle OBDVT Idling jet 42 Main air jet 200 Idling air jet 100 Needle position 5 rd from top Starting jet 85 Mixture control screw open 2 Slide 15 Performance restricto...

Page 49: ...s reserve Final drive ratio 16 38 Chain X Ring 5 8 x 1 4 Bulps headlight H4 12V 60 55W socket P43t parking light 12V 5W socket W2 1x9 5d indicator lamps 12V 1 2W socket W2x4 6d brake rear light 12V 21...

Page 50: ...Collar nuts rocker arm bolts M14x1 5 100 Nm Engine mounting screw M10 45 Nm Ball joint for push rod M8 Loctite 243 25 Nm Sprocket screws on nuts M8 Loctite 243 35 Nm Collar nut swingarm bolt M14x1 5...

Page 51: ...tion switch 11 Compression damping of fork 13 Compression damping of shock absorber 13 Conservation for winter operation 44 Cooling system 34 Correct chain tension 25 Dismounting and mounting the fron...

Page 52: ...ANHANG APPENDIX 1...

Page 53: ...ANHANG APPENDIX 2 660 SMC 2003...

Page 54: ...ANHANG APPENDIX 3 KTM 660 SMC 2003...

Page 55: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321054...

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