History of the KTM SMC & Duke

[arctic954]

Had a few local people ask about my KTM 625 SMC..... and while I was currently doing some of my own research on the bike --- ended up starting a post listing the information I'd come across. This POST ended up as a STICKY in the local forum. Over the last few weeks....I've been trying my best to make sure the information listed is correct.

This by no means is a 100% COMPLETE history, and may contain error's....

So --- if you have some info to share..... please PM me, and we'll polish the turd together. (at this time I have chosen to exclude, RXC/SXC/640 dirt, and SMR race models)

[arctic954]

The TIME LINE ------


- 1996 to 1999, DUKE I 620 (Black Engine LC4 - 609cc)

Bike had good stuff, WP suspension, Magura hardware, and Brembo brakes. Believe it or not -- several people had monster 70HP race versions.... they milled the head to get 11:1 compression, ported & polished, dropped in custom ground cams, and installed larger pistons. A few of these we built up to compete with Honda F3's. Standard carb was either the Mikuni BST-40 or the Edlebrock Quicksilver during later years. Mine came with an FCR41 installed from the previous owner. The Black LC4 motors were known for having crankshaft bearing problems. Several days I can think of I was left strandend on the side of the road ---- leaky oil connections, clutch cables braking (went through 4 of them in 2 years).....squeaky rear brakes.

Would I buy another? Sure.... The RPM guage said it all, which lovingly said..."Beats Per Minute"

- 2000-2002, KTM Duke II 640 (Black Engine LC4 - 625cc) w/ dual exhaust, BBS wheels, 11L tank & seat combo, Mikuni BST-40 carb, and WP Street oriented suspension. (they had less suspension travel than the 640 LC4 Supermoto's)

- 2001, KTM 640 LC4 Supermoto (Black Engine LC4 - 625cc)... Mikuni BST-40 carb, 11L tank/seat, and a single exhaust. It basically was a KTM 640 Dualsport dirt bike with 17's & WP Sumo suspension.

- 2003, KTM 640 LC4 Supermoto (Silver Engine LC4 - 625cc) - this year saw some upgrades to the 640.... mainly the same highflow head as the single exhaust 625/660 smc, but still retained the 11L tank/seat & Mikuni BST 40. Of course, Europe also got the larger version...the single exhaust 660 SMC (654cc)

- 2004, KTM 625 SMC (Silver Engine LC4 - 625cc).... this bike had a dirt bike looking tail, a single can exhaust system, and a different rear sub-frame than the newer dual exhaust 625 smc....but included the racier FCR 41MX carb, smaller 9L gas tank, and the KTM highflow head. People like these bikes, because of the single exhaust --- lesser weight....and you can get a full exhaust system for this bike CHEAP ($300-400 for a full system).... Owners of this bike at times have experienced different oil flow problems (like having to replace intake roller bearings). Apparently the newer dual exhaust version was upgraded with 2 separate Eaton oil pumps.

- 2004, KTM 640 LC4 Supermoto - 'Prestige Racing Edition'. (Euro, Silver Engine LC4 - 625cc, highflow head, single exhaust, BST-40 carb, 11L tank/seat)

- 2004, KTM 450 & 525 SMC - Still looking for better pictures and more information on this one. (In my opinion, they look identical to the SMR) KTM released a version of the 450 & 525 EXC's with 17" supermoto wheels..... they were labeled SMC's. These bikes had the RFS (racing 4 stoke) engine and a 6 speed transmission. They also had a deal where you would also get a FREE set of SMC dirt wheels after buying the bike from the dealer. What I don't know is.... if this SMC was before the SMR and then just simply relabeled or if the 2 existed together. I have a feeling that this bike was actually the first year SMR released in the EURO markets, but simply labeled SMC in the USA. (because most of the info I find says --- USA only) None-the-less this limited edition bike carried the SMC name.

- 2003 to 2006, KTM Duke II 640 (Silver Engine LC4 - 625cc, US and Euro). The bike came out with the dual exhaust design, had the Mikuni BST-40 carb, Marchesini wheels, 11L tank & seat combo, Brembo brakes, WP street oriented suspension, and steel braided lines as standard equipment. Many parts from the Duke II can be interchanged with the 625 SMC.

- 2005 to 2006, KTM decided to have (3) bikes..... (they redesigned the 640 for europe) the KTM 640 LC4 Supermoto (625cc, highflow head, Mikuni bst-40, 11L tank/seat, dual exhaust), the KTM 625 SMC (625cc, highflow head, 9l tank, FCR41MX carb, dual exhaust), and the larger version --- the KTM 660 SMC. (basically an identical looking bike to the 625 SMC, w/ 654cc's and no electric start) KTM decided to only import the 625 SMC and the Duke II 640 to the US. In Europe, the dual exhaust 640 LC4 Supermoto came in several different color combinations. (Blue, White, Orange, Black/Orange, and the all Black/Grey Prestige)

- 2007-2009, KTM 690 SM, at this time production of the KTM 625/640/660 stopped. (US & Europe) The new 690's had 654cc's....biggest changes being - fuel injection, a new counterbalanced crank, a slipper type APTC 'anti-hopping' clutch, 6-speed transmission, Brembo radial mount brakes, steel lines, and an ECU with an integrated idle/cold start system......The standard 690 SM was available in 3 color combinations.....Orange, Black, and Prestige Grey.

- 2008-2009, KTM 690 SM-R, the R version included an orange frame & black Marchesini wheels.

- 2008-2009, 690 SMC (654cc's). Same great stuff as the 2007 690 SM, different look, 3.17 gallon tank capacity, spoke wheels, lighter weight. (307 pounds dry vs. 335.1 pounds dry on the 690 SM)

- 2008-2009, KTM DUKE 690. (654cc's) Different styling, a little heavier than the 690 SMC at 327.4 dry, more road oriented suspension w/ less suspension travel (7.9"-8.3" verses the 10.8"-10.4" travel of the SMC), black Marchesini wheels, and a 3.57 gallon tank. (verses the 3.1 capacity of the SMC)

- 2010 690 Duke R, (690cc, achieved by using a longer stroke) Keihin fuel injection, 12.5/1 compression ratio, 13.5 Litre tank, 327 lbs race weight (includes oil/coolant) w/o fuel, and the R version orange frame/rear shock/carbon bits. (KTM is claiming around 70 HP at the crank)

-------------------------------------------------------------------------------------

As a final recap --- the KTM SMC/SM/Duke's are basically street bikes, with low maintence and high service intervals. (With the DUKE being even more of an all-out street bike with its road based shorter travel suspension) The LC4 motors have more power than the street oriented Suzuki DRZ-400SM. (though...the DRZ has a TON of race parts available) Yes, the SMC's are capable of riding in the dirt...(and the new 690 is even more capable) --- but they are still 300+ pound bikes.

If you want a dirt-race Sumo.... better to start off with a trail bike or MX bike (450/525/530 EXC, WR450, YZF450 - race, CRF450 - race).... or just buy the race oriented, higher maintence, KTM SMR.

If Deal's Gap, road-oriented track days, riding twisties, and the ocassional ride to work are what you want (with a couple fire roads thrown in for good measure)..... then you have the right bike.

[arctic954]

The Original KTM Duke I 620 (609cc)...... 1996 to 1999 ---- the bike that started the revolution.

This bike was based off the 'RXC' dirt bike platform. (and shared plastics/tanks from that bike)
BTW - the best place to find parts for this bike.....is in the United Kingdom E-bay





A picture of my first supermoto..... (with upgraded FCR41 installed)

[arctic954]

2000-2002 KTM Duke II 640 w/ dual exhaust, BBS wheels, 11L tank & seat combo, BST-40 carb....(non-highflow head)



2001 - KTM LC4-E 640 Supermoto (625cc)....



2003 KTM 640 LC4 Supermoto (625cc) single exhaust (Euro)



2003-2004 KTM 660 SMC, (654cc) single exhaust, but with no-electric start. (Euro Only)



2003-2006 - KTM redesigned the KTM Duke II 640 (625cc's).....
This bike had the Mikuni BST-40 carb, Highflow head, 11L tank & seat to match, Marchisini wheels, and WP road oriented suspension.



2004 KTM 450/525 SMC, Pretty much an SMR --- with the SMC badge. Liquid cooled, 6-speed, SOHC, RFS (Racing Four Stroke) engine. (USA only)



2004 KTM 625 SMC (625cc), single exhaust version. (US and Euro)



2004 KTM 640 LC4 Supermoto, Prestige Edition (Euro)



2005-2006 KTM 625 SMC, (625cc) Dual Exhaust Version......(US and Euro)

[arctic954]

2005, KTM 640 Supermoto - Euro only (625cc, dual exhaust, 11L tank/seat, Mikuni BST-40, highflow head, different euro headlight)

The 625 and the 640 had the same LC4 engine (both had 625cc's) -- biggest difference was the carb (BST-40 vs FCR41MX).....the plastic on the 640's were a high-gloss plastic w/ the Decals under a clear-coat.... (unlike the 625cc, which had a dirt-bike like decal on the rad shrouds) The 640 came in several different versions..... 640 Black (which was Black with Orange graphics), Blue, White, Orange, and the all black Prestige.

------------------------------------

THESE PARTS FIT ON THE 625 SMC

BTW - if you go to Munn Racing and look under 'Decals' for this bike... it looks like they aren't available....(the same goes if you ask your local KTM dealer --- unless they know about this, they'll simply say this graphic isn't available) this is because when you buy the radiator shrouds -- the graphic is already on the shroud. (The Black/Orange and Black Prestige radiator shrouds are still available as of 11-25-09 - direct ship from KTM/Austria)

This bike also has a 'comfort gel seat' available..... the 11L Tank and Gel seat are directly swappable to the 625 smc. (and work with the seat latch)

(If you call or e-mail Munn Racing, they are very familiar with what part numbers you will need)









2006-2007 - Europe got the larger CC version..... the 625 on crack.... 660 SMC. (654cc, dual exhaust, 9l tank & 625 smc type seat, highflow head)
--- but with no electric start and apparently came with the BST-40 carb.

[arctic954]

2007 - 2009, KTM 690 SM.....(654cc)



KTM 690 SM Black.....



KTM 690 SM Prestige....



2008 - 2009, KTM 690 SMR.....(654cc)

[arctic954]

2008-2009, KTM released the newly remodeled KTM 690 SMC (654cc).....




2008, They also came out with the new DUKE 690 (654cc)...






2010 - KTM 690 Duke R (true 690cc, created by a longer stroke) w/ 12.5/1 compression ratio. - claimed around 70HP at the crank.

Ready to Race Dry Weight (includes oil/coolant) w/o Fuel -- 327 pounds
Tank Size - 13.5 litres / 3.56 Gallons

This model includes all the good stuff --- Brembo radial brakes, Marchesini forged aluminum wheels, Magura hardware, steel brake lines, and WP street suspension.

[Sjorrit]

This is not correct:

- 2007, KTM decided to release the 'stylish' 690 SMC(It's not the SMC but the normal SM, it came in 2007 and in the same year the SM-R. The SMC came in 2008)

I believe that KTM Europe decided to keep the KTM 640 in production and offered a few different colors that year.
(soon as the new 690 came production for the 640 stopped, the blue blue and white 640 came also out 2005.2006) (this is where the Blue and White 640's came from...the all Black 640 PRESTIGE was released in '05, Euro markets only)

[Paddington]

You also need to include the new 2010 Duke R

[arctic954]

Hey Sjorrit --- info updated.

[B_palmer22]

04's are Single sided exhaust and older style subframe. Subframe, seat, rear fender, airbox are all different. I dont think they made a SMC in 03 in the states.

[Sjorrit]

Your timeline still show the 690 SMC came in 2007 while it actually came mid-2008

[arctic954]

690 sm in 2007, 690 smc in 2008.....right? pretty sure I was still making the changes while you posted back. It should be straight now.

[arctic954]

B_palmer 22 --- thanks for the info.....working on the changes now. Still trying to figure out what KTM did in 2003 w/ the 625, single sided version.

[Sjorrit]

690 sm in 2007, 690 smc in 2008.....right? pretty sure I was still making the changes while you posted back. It should be straight now.

Haha I think so I'm to addicted to this forum

Thanks for your work!

[arctic954]

Please post up any other good bits of info if you think of it......
This will be a nice and shiny turd when we get it done!



Please contribute everybody --- lets make this a good resource!

[Tfunk]

Just to throw a kink in your thread......

What about the limited build 03/04 SMC's that came with two sets of wheels....MX/Supermoto/brakes and had a 525RFS motor?? I know this is a TOTALLY different bike but they were out there in very limited #'s.....

[arctic954]

If you can find me the link to some info & pics, would gladly include them.

[Sjorrit]

Here in the Netherlands is a bikemagazine called Motoplus and they disassembled an 690SM with 50.000km. After those km's the only thing they could find was 2% less compression, lost 2Nm and 2hp, still had 62bhp. But the exhaust valves can be "grinded in the cilinderhead" (don't know how to translate " kleppen inslijpen" from dutch to english) witch should cost 500 euro and it will be good as stock. They used the bike for street and track and even rode it in the winter with salt on the roads.

EDIT: I typed 5000(!) euro, had to be 500.

[arctic954]

wow....now thats durable.

Have also heard of 30,000+ miles out of the 625. To be honest never owned a sportbike past 20,000.

Maybe its finally time to hang on to the SMC for a while.

Its 38 degrees here......'Thanksgiving Day'.... it snowed this morning..... as soon as the roads got dry --- just HAD to go out for a little Sumo ride.

Addicting indeed.

[Paddington]

Duke R:
Duke 690 R
For KTM, the range of single cylinder LC4s represent tradition, legend and future and well as performance, rideability and the smooth, quiet, harmonious running of the engine. When KTM introduced this motor concept in 2007, it elevated single cylinder enjoyment to a level that to date has not been surpassed. With the presentation of the Duke 690 in 2008 KTM caused another sensation among the worldwide community of Duke fans. But KTM wouldn’t be KTM when the ambitious developer wasn’t set on constant improvement and innovation. Now 70 full-blooded hp packed into a vehicle weight of just 148 kg lend the Duke 690 R unrivalled panache. Highest quality components and the unique optics are also typical KTM. As well as the highly potent motor, the 690R also features the orange frame specially reserved for the R models. Carbon mudguards, an extremely sophisticated fork and the new orange rear damper spring are among the outstanding features of the Duke R. Other improvements include an extended maintenance interval and ensure that this very hot street bike will continue to have no serious rivals.

The Duke R is the first 690 who is actually a 690 cubic engine. This is done with a giving it a longer stroke, Sorry if my english isnt good enough. It has 70 Hp from factory. Carbon front fender takes off 300g from the front wheel.


ENGINE TYPE
Single cylinder, 4-stroke

DISPLACEMENT
690 cc

BORE/STROKE
102/84.5 mm

POWER
51.5 kW @ 7500 rpm

TORQUE
70 Nm @ 5500 rpm

COMPRESSION RATIO
12.5:1

STARTER/BATTERY
Electric starter/12V 8.6Ah

TRANSMISSION
6 gears

FUEL SYSTEM
Keihin EFI with EPT (Electr. Power Throttle)

CONTROL
4 V/OHC with roller rocker levers

LUBRICATION
Pressure lubrication with 2 Eaton pumps

ENGINE OIL
Motorex, SAE 10W-60

PRIMARY DRIVE
36:79

FINAL DRIVE
16:40

COOLING
Liquid cooling

CLUTCH
APTCTM slipper clutch, hydraulically operated

ENGINE MANAGEMENT/IGNITION
Keihin EMS

CHASSIS

FRAME
Chromium-Molybdenum trellis frame, powder coated

SUBFRAME
Aluminium

HANDLEBAR
Aluminium, tapered, Ø 28/22 mm

FRONT SUSPENSION
WP-USD Ø 48 mm

REAR SUSPENSION
WP-Monoshock with Pro-Lever linkage

SUSPENSION TRAVEL FRONT/REAR
140/140 mm

FRONT BRAKE
Brembo four piston, radially bolted caliper,


brake disc Ø 320 mm

REAR BRAKE
Brembo single piston, floating caliper,


brake disc Ø 240 mm

WHEELS FRONT/REAR
Cast aluminium wheels 3.50 x 17"; 5.00 x 17"

TYRES FRONT/REAR
120/70 R 17; 160/60 R 17

CHAIN
X-Ring 5/8 x 1/4"

SILENCER
Stainless steel underfloor silencer with regulated catalytic converter

STEERING HEAD ANGLE
63.5°

TRAIL
115 mm

WHEEL BASE
1,472 ± 15 mm

GROUND CLEARANCE
155 mm

SEAT HEIGHT
865 mm

TANK CAPACITY
approx. 13.5 litres/2.5 litres reserve

WEIGHT (READY TO RACE)
approx. 148.5 kg (without fuel)

[arctic954]

Thanks for the info --- I've taken a few key points and highlighted them above.

[arctic954]

2004 KTM 450/525 SMC TEXT added..... still digging for pics and better info

KTM 690 SM-R..... PIC added.....still researching more info on the bike

[arctic954]

Per a PM, information on the 2004 KTM 625 SMC, has been updated.

[goodcat8]

This whole thread is saving me hundreds of stupid questions I'd otherwise be asking everyone on here.

[yantalas]

ive got a 2000 lc4 supermoto bought new in early june 2000 wp usd forks mikuni bst, behr rims silver and black with over 20,000 miles.

[arctic954]

Have any good pics? It would be worthy of sticky KTM bliss...... I'll post it up w/ some of your info. PM me with the info --- and I'll update the thread.

[yzedf]

The 2004 525 SMC is not much like a SMR but a SX. SX frame, swing arm etc. I was told that of the showroom floor it was a 4 spd but that most were upgraded to 6 spd post sale.

here is mine with the 3.1 gallon tank and akrapovic exhaust.

[arctic954]

wow --- it sure does have longer travel suspension than the SMR!

Thanks for posting that up. Best pic I've seen yet. LOL --- Google will probably now hit this thread with your pic.

[oyove]

Duke R:


WHEELS FRONT/REAR
Cast aluminium wheels 3.50 x 17"; 5.00 x 17"

The DukeR has forged marchesini wheels...

[lewis87]

In post #5 you say the 660 SMC comes with the BST40 carb, but it comes with an FCR41, same as the 625 SMC.

[arctic954]

Thanks for the info on the 660 SMC. Was waiting for a 'local' to chime in on that one.

[J Banning]

Great thread! Any info on the 660 Van Den Bosch replicas?

[arctic954]

man.... I've got a TON of info to update to this. I really want to include a history of all the SMR models.... not to mention add the SuperDukes and the new 990 & SM-T.

Unfortunately, I can no longer edit the original content. Have been e-mailing Moderators to get back my editing wrights.

------ um.... Van Den Bosch? Post up a pic..... I'll then dig some more....

[J Banning]

um.... Van Den Bosch? Post up a pic..... I'll then dig some more....

I've heard 70+ hp, light weight, kick start only, carbon fiber tank & fenders. Looks like the actual name is "KTM 660 Supermoto Factory Replica" and it is sofa king sweet!!

Some info in a post here:
http://www.supermotojunkie.com/showthread.php?t=36450

Picture from SMR Magazine, says it was a 2002 model:
http://www.supermotojunkie.com/showp...3&postcount=30
http://www.supermotojunkie.com/showp...8&postcount=33


-B

[arctic954]

wow...... nice find.

[lewis87]

They are not replicas, they are actual KTM factory race bikes. You could order them through KTM dealers but they never came road legal, but it's easy to make them legal to ride on the road in Europe.

Here is a link to a thread on a UK KTM forum with lots of pics, these bikes have all the best parts, the whole subframe is carbon fibre. They weigh about 110kg and I have heard people claiming as much as 80bhp! But most people say they are around 70.

http://www.ktmforum.co.uk/showthread...rk-in-progress

[J Banning]

Thanks Lewis87!

[Spanky Noodle]

Here is my 04 625 SMC!! Got 42,000 miles. Love it!! Had a few problems.. Good thing I got extended warranty. It would have been really expensive if I had to pay out of pocket. Let see, main bearings went bad to due a defective crank. Both Intake and Exhaust rocker arm bearings failed and ruined cam. 4th idler gear came apart. Replaced all gears and shafts in transmission. With all the problems I had. I still love my SMC!! What blast to ride!!

BTW All LC4 engines have TWO oil pumps. One pump is used for the crank and piston. Second pump is used for transmission..

[Duke660]

I have been following this with interest.

does anyone have the specifcations of the 2003 660cc motor, with no electric start. I got one that was slotted into a 2002 Duke frame for me. But all I know about the motor is that it was a 660 SMC from Europe. It has the oil resovoir behind the cylinder and does not run the oil hose to the holding tank on the frame.

bike now has a 660cc engine, slide carb and Sibring big bore pipes.




and can shred a cut slick on a "bad-day"



thanks
Tony

[lewis87]

Cool bike Duke660

There are quite a few 660 owners on the ktmforum.co.uk who may be able to help. Owners who have had their bikes on a dyno claim 62-65bhp and around 48-50 ft-lbs of torque.



There are these specs too but I'm not sure if they are correct, comparison of the 660 and 625:


660:
Displacement: 654.00 ccm (39.91 cubic inches)
Torque: 43.00 Nm (4.4 kgf-m or 31.7 ft.lbs) @ 4000 RPM
Compression: 11.5:1
Bore x stroke: 102.0 x 80.0 mm (4.0 x 3.1 inches)



625:
Displacement: 625.00 ccm (38.14 cubic inches)
Torque: 41.00 Nm (4.2 kgf-m or 30.2 ft.lbs) @ 3250 RPM
Compression: 11.7:1
Bore x stroke: 101.0 x 78.0 mm (4.0 x 3.1 inches)

[Duke660]

thanks for the info.
last time I had the bike on a dyno was back in South Africa ( 2004) and then it was at altitude which robs you a few horses, but even then we saw 61hp.
I'd guess we now around the 65hp at sea level, with the Sibring pipes and slide carby making the huge difference.

cheers
Tony