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KTM 660 SMC 2003 - User Manual

KTM 660 SMC 2003
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OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2003
BEDIENUNGSANLEITUNG
Art.Nr. 3.210.54 9/2002
660 SMC

Table of Contents

Questions and Answers

  • T
    Timothy NguyenAug 17, 2025
    How to reduce high oil consumption in a KTM Motorcycle?
    • J
      Jonathan CannonAug 17, 2025
      To address high oil consumption in your KTM Motorcycle: * Ensure the gearing ventilation hose is not buckled; replace it if necessary. * Check the engine oil level when the engine is warm and correct if needed. * Use a thicker engine oil, referring to the engine oil specifications.
  • W
    william31Aug 20, 2025
    What to do if KTM 660 SMC 2003 Motorcycle engine will not reach full power?
    • L
      Lindsey HallAug 20, 2025
      If your KTM Motorcycle engine won't reach its full power, begin by cleaning and inspecting the fuel system and carburetor. Replace the float if necessary. Clean or replace the air filter. Inspect the exhaust system for damage and replace the glass fiber yarn in the exhaust silencer. Adjust the valve gap. Check the setting of the hand decompression cable. Have the ignition system checked.
  • K
    kimberlyharrisAug 25, 2025
    Why does my KTM 660 SMC 2003 Motorcycle engine get too hot?
    • D
      Douglas BrownAug 25, 2025
      If your KTM Motorcycle engine is overheating, refill the cooling liquid and check the cooling system for leaks. Ensure there is adequate airflow and clean the radiators with a water jet. Replace the cooling liquid, using antifreeze. Shorten or replace any bent cooling hoses. Remove and inspect the thermostat, ensuring it opens at 70°C (158°F), and replace if defective.
  • D
    Diana JordanAug 28, 2025
    What causes a KTM Motorcycle engine to stop or sputter in the carburetor?
    • T
      Tracey WoodAug 28, 2025
      If your KTM Motorcycle engine stops or sputters in the carburetor, clean and check the fuel system and carburetor. Also, check the intake flange and carburetor to ensure they are firmly set.
  • V
    Victoria ChaneyAug 31, 2025
    What to do if KTM 660 SMC 2003 engine does not rev high?
    • S
      stephen59Aug 31, 2025
      If your KTM Motorcycle engine does not rev high, dismount the carburetor and check if it is worn out due to the fuel level being too high because the float needle valve is dirty or worn out.
  • C
    Cynthia TranSep 4, 2025
    Why KTM Motorcycle engine does not rev high?
    • J
      Jack AustinSep 4, 2025
      If your KTM Motorcycle engine does not rev high, tighten the loose carburetor jets. Have the electronical ignition system checked.
  • M
    mcconnellsamuelSep 8, 2025
    What causes all lamps to blow out on a KTM Motorcycle?
    • A
      April AndersonSep 8, 2025
      If all the switched-on lamps in your KTM Motorcycle have blown out, remove the right side cover and control the connections. Have the capacitor and voltage regulator checked.
  • S
    spearschristopherNov 12, 2025
    How to fix a KTM Motorcycle engine that will not start?
    • N
      Nicholas BlackburnNov 12, 2025
      If your KTM Motorcycle engine won't start, first ensure the ignition and emergency OFF switch are on, the fuel tap is open, and there's sufficient fuel in the tank. Avoid using the choke unnecessarily. If the motorcycle has been idle for over a week, drain the old fuel from the float chamber. If fuel supply is interrupted, close the fuel tap, detach the fuel hose at the carburetor, and direct it into a container. If fuel leaks, clean the carburetor; if not, inspect the tank ventilation and clean the fuel tap. For a flooded engine, use the hand decompression lever, fully rev up the engine, and actuate the kickstarter 5 to 10 times. Then, attempt to start the engine. If it still fails, remove and dry the spark plug. Clean or replace the spark plug, setting the electrode gap to 0.9 mm. Check ...

Summary

Operation Instruments

Serial Number Locations

Instructions for locating and recording chassis and engine serial numbers.

Clutch Lever

Description and adjustment of the clutch lever on the handlebar.

Hand Decompression Lever

Usage of the hand decompression lever for starting and pushing the motorcycle.

Hand Brake Lever

Location and adjustment of the hand brake lever for the front wheel.

Electronic Speedometer and Tripmaster

Indicator Lamps

Explanation of indicator lamp functions like turn signals and high beam.

Electronic Speedometer

Overview of the digital speedometer display and its modes.

Tripmaster Switch Functions

Detailed explanation of tripmaster modes and button operations.

Control Switches and Fuel System

Combination Switch

Operation of the light switch and engine stop button.

Flasher Switch

Location and function of the turn signal switch.

Filler Cap

Instructions for opening and closing the fuel filler cap.

Fuel Tap

Operation of the fuel tap in OFF, ON, and RES positions.

Choke

How to use the choke for cold engine starts.

Engine Starting and Control Devices

Hot Start Device

Function of the hot start device for hot engine starts.

Shift Lever

Identification of gear positions and neutral.

Kickstarter

Location and operation of the kickstarter.

Foot Brake Pedal

Location and basic position adjustment of the foot brake pedal.

Handlebar Lock

Procedure for locking the handlebar using the ignition lock.

Chassis Suspension Adjustments

Fork Damping Adjustments

Adjusting compression and rebound damping for the front fork.

Shock Absorber Damping Adjustments

Adjusting compression and rebound damping for the rear shock absorber.

Starting the Motorcycle

General Tips and Warnings

Essential advice and safety warnings before initial operation.

Running-in Procedure

Guidelines for breaking in the engine during the first 1000 km.

Driving Instructions

Pre-Start Checks

Essential checks to perform before each motorcycle start.

Riding Procedures

Riding Safety and Fuel Handling

Periodic Maintenance Schedule

Maintenance Work on Chassis and Engine

Suspension Setup and Adjustment

Telescopic Fork Setup and Spring Replacement

Chain Maintenance and Tension

Chain Care and Wear

Brake System Components

Front Brake Maintenance

Rear Brake Maintenance

Brake Pedal and Rear Pad Adjustments

Wheel Mounting and Dismounting

Wheel and Sensor Checks

Tripmaster Display Functions

Lighting System Maintenance

Cooling System

Air Filter and Exhaust System Maintenance

Throttle, Clutch, and Decompression Adjustments

Hydraulic Clutch and Carburetor Service

Carburetor Adjustments

Engine Oil and Oil Circuit

Engine Oil and Microfilter Maintenance

Oil Filter Maintenance

Trouble Shooting

KTM 660 SMC 2003 Specifications

General IconGeneral
BrandKTM
Model660 SMC 2003
CategoryMotorcycle
LanguageEnglish

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