KTM 690 SMC R 2016 Series Manual

SETUP INSTRUCTIONS 2016

690 SMC R

Art. no. 3213429en

INTRODUCTION 1

*3213429en*

3213429en

11/2015

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest

of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It

is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically 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, misprints, and other errors. The models portrayed partly contain special equipment that does not

belong to the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, 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 GmbH

5230 Mattighofen, Austria

This document is valid for the following models:

690 SMC R EU (F9703P9)

690 SMC R AU (F9760P9)

1 MEANS OF REPRESENTATION 2

1.1 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).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained

in the glossary.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

S00791-10

–Remove the straps and box.

S00809-10

–Remove the adhesive tape in the upper area of the motorcycle.

S00810-10

–Roll down the film at the sides.

Info

To avoid damaging the motorcycle during unpacking, leave the other films

on the vehicle until you have finished work on the vehicle.

–Remove the separate enclosure and unpack it. Check the separate enclosure for

completeness.

–Check the vehicle for transport damage.

S00794-10

–Remove the controls from the transport holder.

–Remove the screws and handlebar clamps.

–Remove the transport holder.

S00795-10

–Remove screw of the right hand guard.

S00796-10

–Position the controls on the right half of the handlebar.

Info

The figure shows how to route the cable and lines.

–Mount the screws.

2 SETUP 4

S00797-10

–Position the handlebar.

–Position the handlebar clamps. Mount the four screws and tighten evenly.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

The markings of the handlebar scale are located centrally between the han-

dlebar clamps.

Markings face backwards.

S00798-10

–Position the controls on the left half of the handlebar.

–Mount the screws.

S00799-10

–Position all controls in their exact positions on the handlebar.

–Tighten screws and .

Guideline

Screw, throttle grip M5 3.5 Nm

(2.58 lbf ft)

Screw, brake assembly M6 5 Nm (3.7 lbf ft)

–Check the throttle grip for smooth operation.

–Mount and tighten the screw of the right hand guard.

–Tighten screws and .

Guideline

Screw, combination switch, left M5 3.5 Nm

(2.58 lbf ft)

Screw, clutch assembly M6 5 Nm (3.7 lbf ft)

K00062-01

–Mount and tighten the rear mirror adapter and rear mirror on both sides.

100308-01

–Mount the footrests with springs and pins. Secure the pins using washers and cot-

ter pins.

Pliers for footrest spring (58429083000)

–Remove the protective plastic.

–Carefully loosen and remove the tension belt over the link fork.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tension belts around the lower triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the palette.

2 SETUP 5

S00801-10

–Recharge the battery. ( p. 7)

–Install the battery. ( p. 8)

–Plug in connector on the starter relay.

S00802-10

–Remove the rear fairing. ( p. 10)

–Four markings are found on the underside of the rear fairing. At these location,

drill holes to the specified diameter in three stages.

Guideline

Hole diameter for grab handles 14.5 mm (0.571 in)

S00803-10

–Remove screws .

–Fit the rear fairing. ( p. 10)

201901-10

–Mount the reflector.

Operation as a 2-seater

–Mount rear footrest bracket. ( p. 10)

Operation as a 1-seater (only if requested by customer)

Warning

Forfeiture of homologation and insurance cover The vehicle is

homologated as 2-seater. If the heel protector is fitted instead of the

footrest bracket, the vehicle no longer conforms to the homologation and

must not be operated in this form without alterations to the registration

papers.

–Set up and operate the vehicle as a 2-seater or have changes made

to the registration papers.

–Mount heel protector. ( p. 11)

–Refuel. ( p. 11)

–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-

dover to the customer.

–Set the kilometers or miles. ( p. 12)

3 WORK 6

3.1 Removing the seat

101977-10

–Pull on strap and raise the rear of the seat at the same time.

–Pull back the seat and lift it off.

3.2 Mounting the seat

101988-10

–Hook slot of the seat onto screw , press the rear downward and at the same time 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.

–Check, finally, that the seat is correctly mounted.

3.3 Removing the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the seat. ( p. 6)

B01974-10

Main work

–Remove battery cover .

–Pull the EFI control unit off of the holder and set it to one side.

3 WORK 7

S00622-10

–Disconnect negative cable from the battery.

–Take off the positive terminal cover .

S00620-10

–Disconnect the ABS connection cable and positive cable from the battery.

S00621-10

–Remove screws .

–Pull retaining bracket of the battery forward and remove it.

–Lift the battery up and out.

Info

Never operate the motorcycle with a discharged battery or without a battery.

In both cases, electrical components and safety devices can be damaged.

The vehicle will therefore no longer be roadworthy.

3.4 Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

Environmental hazard The battery contains elements that are harmful to the environment.

–Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner.

Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.

Warning

Environmental hazard Hazardous substances cause environmental damage.

–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Even when there is no load on the battery, it still loses power steadily.

The charging level and the method of charging are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This

reduces the battery capacity.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the

battery.

The battery is maintenance-free, which means that the acid level does not need to be checked.

3 WORK 8

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the seat. ( p. 6)

–Remove the battery. ( p. 6)

S01013-10

Main work

–Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the alternator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove lid .

Charge the battery with a maximum of 10% of the capacity specified on the

battery housing .

–Switch off the battery charger after charging and disconnect from the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the

motorcycle is not in use

3 months

Finishing work

–Install the battery. ( p. 8)

–Mount the seat. ( p. 6)

–Set the clock. ( p. 12)

3.5 Installing the battery

S00621-11

Main work

–Insert the battery into the battery compartment with the terminals facing rearward.

Battery (YTZ10S)

–Position retaining bracket and mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

S00623-10

–Position washer , positive cable , and ABS connection cable .

–Mount and tighten screw .

Guideline

Screw, battery terminal M6 4.5 Nm

(3.32 lbf ft)

S00622-11

–Position positive terminal cover .

–Position washer and negative cable , and mount and tighten the screw.

Guideline

Screw, battery terminal M6 4.5 Nm

(3.32 lbf ft)

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