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KTM 1190 RC8 AUS, Owner'S Manual, Page: 202 / 250

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KTM 1190 RC8 AUS Owner'S Manual Download Page 202

MAINTENANCE WORK ON FRAME AND ENGINE

200

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.

–

Place a suitable container under the engine.

100774-10

–

Remove screws

. Take off oil filter cover

with the O-ring.

100775-10

–

Pull oil filter

out of the oil filter housing.

Circlip pliers reverse (51012011000)

–

Completely drain the engine oil.

–

Clean the parts and the sealing area thoroughly.

Summary of Contents for 1190 RC8 AUS

Page 1: ...OWNER S MANUAL 2010 1190 RC8 R EU UK 1190 RC8 R AUS 1190 RC8 R FR 1190 RC8 R JP Art no 3211525en...

Page 2: ......

Page 3: ...oing to print However it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG specificall...

Page 4: ...s 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 proce...

Page 5: ...Combination instrument function buttons on handlebar 25 Combination instrument activation and test 26 Display 27 Info display 28 Indicator lamps 29 Notes warnings on the combination instrument 30 Over...

Page 6: ...rting up 89 Shifting riding 90 Braking 93 Stopping parking 94 Refueling 95 SERVICE SCHEDULE 97 Service schedule 97 MAINTENANCE WORK ON FRAME AND ENGINE 100 Jacking up motorcycle front 100 Taking front...

Page 7: ...pressure 152 Removing the seat 153 Fitting the seat 153 Removing the passenger seat 154 Mounting the passenger seat 154 Mounting the helmet lock on the vehicle 155 Removing the battery x 155 Installin...

Page 8: ...ERATION 218 Conservation for winter operation 218 STORAGE 219 Storage 219 Putting into operation after storage 220 TECHNICAL DATA ENGINE 221 Capacity engine oil 222 Capacity coolant 222 TECHNICAL DATA...

Page 9: ...ialist knowledge and technical understanding In the interests of your own safety have these jobs done in an authorized KTM RC8 workshop There your motorcycle will be handled opti mally by specially tr...

Page 10: ...ice or replace worn parts before the limit specified in the service schedule is reached Pay careful attention to the prescribed running in period and inspection and maintenance intervals Close adheren...

Page 11: ...s used for screw connections be sure to comply with the manufacturer s specific instructions on its usage Parts that you want to reuse following repairs and servicing should be cleaned and checked for...

Page 12: ...p to avoid such problems and con flicts To ensure the future of motorcycle sport make sure you use the motorcycle legally demonstrate a consciousness for the environ ment and respect the rights of oth...

Page 13: ...amage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual Be sure to read this owner s...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side 100652 10...

Page 15: ...VIEW OF VEHICLE 13 1 Clutch lever 2 Light switch headlight flasher switch indicator switch horn button 3 Filler cap 4 Seat 5 Seat lock 6 Oil dipstick 7 Side stand 8 Shift lever 9 Passenger footrests...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side 100653 10...

Page 17: ...t 2 Supporting strap 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Hand brake lever 7 Chassis number type label 8 Rear brake caliper 9 Foot brake lever 10 Eng...

Page 18: ...frame above the vehicle identification number 4 2 Key number 700222 01 The key number Code number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD...

Page 19: ...OF SERIAL NUMBERS 17 4 3 Engine number 100655 10 The engine number is stamped on the right side of the engine 4 4 Fork part number 100656 10 The fork part number is stamped on the inner side of the f...

Page 20: ...ber 100657 10 The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring towards the rear 4 6 Steering damper part number 100658 10 The steering damper...

Page 21: ...clutch lever is fitted on the left side of the handlebar The clutch is hydraulic and self adjusting 5 2 Hand brake lever 100660 10 The hand brake lever is fitted on the right side of the handlebar The...

Page 22: ...witched on High beam on The light switch is in the upper position In this position the low beam the high beam and the tail light are switched on 5 4 Headlight flasher switch 100662 10 The headlight fl...

Page 23: ...the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the tur...

Page 24: ...black ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and th...

Page 25: ...e ignition key is withdrawn The red warning lamp flashes at 15 second intervals after one minute The red warning lamp can also indicate errors by flashing Info The ignition key contains electronic com...

Page 26: ...CONTROLS 24 5 11 Combination instrument overview 400580 10 1 Display p 27 2 Function buttons 3 Indicator lamps p 29 4 Info display p 28...

Page 27: ...button is fitted on the handlebar front left The LAP button is fitted on the handlebar rear left MODE button Changes to the next item on the info display in ROAD mode and in RACE mode LAP button Chan...

Page 28: ...nts of the tachometer light up in and switch off in sequence The speed display counts from 0 to 300 and back The remaining display segments outside the info display light up briefly The KTM logo appea...

Page 29: ...xcessive speed range of the engine The speed is displayed in kilometers per hour km h or in miles per hour Mph The time appears in segment Info After reconnecting the battery or changing the fuse the...

Page 30: ...ublic roads Menu 2 is RACE mode for riding on race tracks It allows riders to time laps themselves If the general warning lamp lights up the corresponding message is shown periodically in the info dis...

Page 31: ...ched The idle speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on EFI warning lamp MIL lights up flashes r...

Page 32: ...ment 400476 01 LOW FUEL appears on the info display if the minimum range falls below the specified value Distance 20 km 12 4 mi 400471 01 LOW BATTERY appears on the info display if the battery voltage...

Page 33: ...falls below the specified value Distance 500 km 310 7 mi 400474 01 HIGH TEMP appears on the info display if the coolant temperature rises above the specified value Coolant temperature 120 C 248 F 400...

Page 34: ...lant temperature sensor values differs by more than the specified value Coolant temperature 10 C 50 F 400467 01 ICE appears on the info display if the external temperature falls below the specified va...

Page 35: ...CONTROLS 33...

Page 36: ...CONTROLS 34 5 18 Overview of ROAD mode 400942 10...

Page 37: ...rip 1 shows the distance covered since the last reset For example between two refueling stops Trip 1 is always running and counts up to 9999 9 Time 1 shows the journey time on the basis of Trip 1 and...

Page 38: ...ast reset For example between two refueling stops Trip 2 is always running and counts up to 9999 9 Time 2 shows the journey time on the basis of Trip 2 and resumes running as soon as a speed signal is...

Page 39: ...ed since the fuel reserve level was reached Info This is displayed only after you reach the fuel reserve level OuterTemp shows the external temperature The external temperature can be switched on and...

Page 40: ...ter you reach the fuel reserve level MinRange shows the minimum range you can cover with the fuel reserve MaxRange shows the maximum range you can cover with the fuel reserve The possible range of the...

Page 41: ...STANCE TO Next Service appears in the info display DISTANCE TO Next Service shows the distance before the next service is necessary Press the button No function Press the button No function Press the...

Page 42: ...CONTROLS 40 5 24 Overview of RACE mode 400943 10...

Page 43: ...stopwatch is running in the background If a P appears after LAPSTOGO the stopwatch in the background is active but waiting for a speed signal The time is not running This function is controlled by th...

Page 44: ...ears after TOPSPEED the stopwatch is not running in the background This function is controlled by the button LAP TOPSPEED shows the highest lap speed LastLap shows the maximum speed of the last lap La...

Page 45: ...P LastLap appears in the info display LAP shows the selected lap BESTLAP shows the number of the lap with the best lap time LastLap shows the time of the lap behind LAP Lap shows the difference to the...

Page 46: ...ws the lap in which the highest maximum speed was reached TopSpeed shows maximum speed of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press...

Page 47: ...since the last reset For example between two refuel ing stops RaceTrip is always running and counts up to 999 9 MaxRPM shows the highest engine speed reached during the RaceTrip TopSpeed shows the hi...

Page 48: ...CONTROLS 46 5 30 Overview of SET UP mode 400945 01...

Page 49: ...CONTROLS 47 Settings in SET UP mode CHANGE MODE menu SET CLOCK menu SETTINGS menu UNITS menu OPTIONS menu EXIT SETUP menu...

Page 50: ...ay On the UNITS menu you can set the units for measuring speed distance and temperature On the OPTIONS menu you can switch the tire pressure check and external temperature display on off available as...

Page 51: ...s Press the MODE button briefly On the CHANGE MODE menu you can select between ROAD and RACE mode Press the button Changes the menu Press the button Changes the menu Press the button and the button fo...

Page 52: ...OCK in the info display Press the MODE button briefly You can set the clock on the SET CLOCK menu Press the button Increases the value Press the button Decreases the value Press the button and the but...

Page 53: ...ton On the SET NUM LAPS menu you set the number of laps to cover in RACE mode On the TRIP F RESET menu you can set the reaction time of the fuel reserve display to changes of the fuel level On the BAC...

Page 54: ...y Press the MODE button briefly Press the MODE button briefly On the SHIFT RPMS menu you can activate the shift warning light Press the button Increases the value Press the button Decreases the value...

Page 55: ...the MODE button briefly Press the button once until the symbol shows LAP BLANK T in the info display Press the MODE button briefly On the LAP BLANK T menu you set the lap blank time of the LAP button...

Page 56: ...utton briefly Press the button twice until the symbol is on SET NUM LAPS in the info display Press the MODE button briefly On the SET NUM LAPS menu you set the number of laps to cover in RACE mode Pre...

Page 57: ...e button three times until the symbol shows TRIP F RESET in the info dis play Press the MODE button briefly On the TRIP F RESET menu you can set the reaction time of the fuel reserve display to change...

Page 58: ...uring speed and distance On the SET C F menu you can set the unit for the temperature display On the BACK menu you can switch back to the SET UP menu The symbol shows which menu you can activate with...

Page 59: ...the info display Press the MODE button briefly Press the MODE button briefly On the SET KM MILES menu you can set the units for measuring speed and distance Press the button Changes the unit Press th...

Page 60: ...MODE button briefly Press the button once until the symbol shows SET C F in the info display Press the MODE button briefly On the SET C F menu you can set the unit for the temperature display Press th...

Page 61: ...f available as an accessory On the OPTION OUTTEMP menu you can switch the external temperature display on off On the BACK menu you can switch back to the SET UP menu The symbol shows which menu you ca...

Page 62: ...tton briefly Press the MODE button briefly On the OPTION TPMS menu you can switch the tire pressure check on off available as an accessory Press the button Switches the tire pressure display on off Pr...

Page 63: ...the symbol shows OPTION OUTTEMP in the info display Press the MODE button briefly On the OPTION OUTTEMP menu you can switch the external temperature display on off Press the button Switches the extern...

Page 64: ...s to the SET UP menu no function Next display mode FUELRANGE menu No function No function The display changes to the SET UP menu No function Next display mode DISTANCE TO Next Service menu No function...

Page 65: ...menu in front of the arrow is selected The menu in front of the arrow is selected CHANGE MODE menu Changes the menu Changes the menu No function Open and exit CHANGE MODE Open and exit CHANGE MODE SE...

Page 66: ...nu in front of the arrow is selected SET KM MILES menu Changes the unit Changes the unit No function Open and exit SET KM MILES Open and exit SET KM MILES SET C F menu Changes the unit Changes the uni...

Page 67: ...CE Mode The igni tion is on The motor cycle is stationary Menu can be activated Odometer menu ODO Trip 1 Odometer menu ODO Trip 2 FUELDISTANCE menu FUELRANGE menu DISTANCE TO Next Service menu LAPSTOG...

Page 68: ...e igni tion is on RACE Mode The igni tion is on The motor cycle is stationary RACE Mode The igni tion is on The motor cycle is stationary Menu can be activated TRIP F RESET menu UNITS menu SET KM MILE...

Page 69: ...isplayed Press the MODE button briefly Next display mode 5 46 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE Mode 400447 01 Press the MODE button briefly and r...

Page 70: ...ges to the SET UP menu Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 5 48 Setting the clock with SET CLOCK Condition The i...

Page 71: ...0460 01 Press the button and the button for 3 5 seconds Press the button twice until the symbol appears in front of SETTINGS in the info display Press the MODE button briefly Press the MODE button bri...

Page 72: ...settings are stored and the display changes to the SETTING menu Info At delivery RPM1 is set to 10000 and RPM2 to 10500 Press the button briefly and repeatedly until the symbol shows BACK in the info...

Page 73: ...h LAP BLANK T you can prevent the lap from being timed too short This may happen if you accidentally press the LAP button twice in a row Set the blank time of the LAP button with the button or the but...

Page 74: ...utton briefly TOTAL LAPS appears in the info display with the number of laps Info When delivered the number of TOTAL LAPS is set to 99 laps Set the number of laps with the button or the button Info Yo...

Page 75: ...button briefly TRIPF RESET appears in the info display with the reaction time Info At delivery TRIPF RESET is set to 300 seconds Set the reaction time of the fuel reserve display with the button or th...

Page 76: ...info display Press the MODE button briefly Press the MODE button briefly The selected unit appears on the left of the display Select the unit with the button or the button Press the MODE button briefl...

Page 77: ...button briefly The selected unit appears on the left of the display Select the unit with the button or the button Press the MODE button briefly The settings are stored and the display changes to the...

Page 78: ...briefly You see ENABLED or DISABLED in the info display You can switch the external temperature display on off with the button or the but ton Press the MODE button briefly The settings are stored and...

Page 79: ...of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must b...

Page 80: ...t it is closed correctly Change cloth ing that came into contact with fuel Immediately clean skin that came into contact with fuel using soap and water Close the filler cap Push down the filler cap sl...

Page 81: ...CONTROLS 79 5 59 Seat lock 100669 10 The seat lock is behind the seat It can be locked with the ignition key 5 60 Tool set 100670 10 The tool set is in the storage compartment under the seat...

Page 82: ...ion if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the jour ney Always remove the helmet lock before starting out 5 62 Pa...

Page 83: ...S 81 5 63 Shift lever 100673 10 The shift lever is mounted on the left of the engine 100674 10 The gear positions can be seen in the picture The neutral or idle position is between the first and secon...

Page 84: ...ar brake 5 65 Side stand 100676 10 The side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand...

Page 85: ...terns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable ha...

Page 86: ...e lever p 135 Adjust the foot brake lever p 125 Adjust the shift lever p 120 Get used to handling the vehicle on suitable terrain before making a longer trip Try also to ride as slowly as possible to...

Page 87: ...ndling characteristics at high speed Adapt your speed according to your payload If the motorcycle is loaded with luggage ride more slowly Maximum speed with luggage 130 km h 80 8 mph Warning Danger of...

Page 88: ...aggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted...

Page 89: ...e fuel level Check the chain tension p 128 Clean the chain p 126 Check the tire condition p 150 Check the tire pressure p 152 Check the front brake fluid level p 136 Check the rear brake fluid level p...

Page 90: ...in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safe...

Page 91: ...ing the engine DO NOT apply the throttle If you apply the throttle during the starting procedure the engine management shuts off the injectors and the engine will not start Press the starter for a max...

Page 92: ...key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle...

Page 93: ...es have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and wi...

Page 94: ...clutch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting of...

Page 95: ...Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Danger of accidents Reduced braking effect caused by spo...

Page 96: ...down two gears but do not race the engine You will require less braking force and the brakes will not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never...

Page 97: ...continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency OFF switch is provided for emergency situations...

Page 98: ...ontact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info This motorcyc...

Page 99: ...that brake lines are undamaged and free of leaks Check the rear brake fluid level p 139 Check the free travel of the foot brake lever p 125 Check that the shock absorber and fork are leak tight If ne...

Page 100: ...reeze and coolant level Check the wiring harness of the throttle valve body for damage and correct routing x Check cables for damage and kink free routing x Check that the cables are undamaged routed...

Page 101: ...ness and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride x Make the service entry in KTM DEALER NET and in the service record x K10N Once after 1 000 km 621...

Page 102: ...to the straight ahead position Align the work stand at the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the motorc...

Page 103: ...work stand Work stand adapter 61029055120 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the link fork and the adapters and jack up the motorcycle 9 4 Taking the rear...

Page 104: ...screw up against the stop with force set the last discernible click as the last position These adjustments should be understood as a guideline and should always be the basis of your own personal chas...

Page 105: ...ing to the fork type Guideline Compression damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce sus...

Page 106: ...ype Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 9 8 A...

Page 107: ...type Guideline Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload turn counterclockwise to reduce spring prelo...

Page 108: ...ranges Dual Compression Control The terms low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed of the motorcycle Changes in the low speed r...

Page 109: ...o the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockw...

Page 110: ...o the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to...

Page 111: ...se to reduce damping 9 14 Adjusting the spring preload of the shock absorber x Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Foll...

Page 112: ...emove 100690 01 Turn the adjusting ring counterclockwise with the wrench from the tool kit until the spring is no longer under tension Hook wrench 69012022000 Extension 60012060000 Turn the adjusting...

Page 113: ...the manner of riding style and the road conditions For high speeds an adjustment with high damping can be chosen in order to use the steer ing damping function optimally In slow tight bends intensive...

Page 114: ...ns by turning the adjust screw clockwise towards Guideline Steering damper adjustment range 1 32 clicks Recommended range for use 1 20 clicks Standard 1 click Info Do not change the adjustment of the...

Page 115: ...eans of the fork leg clamp and at the rear by the eccentric shaft The fork legs can be clamped at three positions in the triple clamps Upper triple clamp flush with upper edge of fork legs 0 mm 0 in U...

Page 116: ...oosen screw of the handlebar stub Info Loosen the screws far enough to prevent damage to the lacquer when the fork legs are moved Make the adjustments first on one fork leg and then on the other When...

Page 117: ...e vehi cle to become more stable but also more difficult to handle 100694 10 Tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 1...

Page 118: ...de behavior Following modifications ride slowly at first to get the feel of the new ride behavior 100696 10 Loosen screw but do not remove it 100697 10 Turn eccentric shaft to the desired position usi...

Page 119: ...est system enables an individual setting of the footrest height and an individual adjustment of the controls The lower footrest position enables a more comfortable knee angle the upper footrest posi t...

Page 120: ...cket with spacers and screws Guideline Standard Upper position Info The adjustable footrest bracket enables a more comfortable lower footrest posi tion or a sporting upper footrest position 100701 01...

Page 121: ...MAINTENANCE WORK ON FRAME AND ENGINE 119 100702 01 Repeat adjustment work on the footrest bracket on the other side Adjust the shift lever p 120 Adjust the foot brake lever p 125...

Page 122: ...shift lever stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tighten screw Guideline Screw shift lever stub M6 10 Nm 7 4 lbf ft Loctite 24...

Page 123: ...5 130 mm 4 53 5 12 in Loosen the counter nuts Adjust the shift shaft Info Make the same adjustments on both sides After the counter nuts have been tightened the bearings of the shift shaft must be cen...

Page 124: ...e shift shaft in two different positions Guideline Standard Shift lever lower drill hole shift shaft lower drill hole Shift power low long shift travel Shift lever lower drill hole shift shaft upper d...

Page 125: ...osition of the shift lever or a low position of the shift lever Info If you turn the reverse shift shaft 2 teeth on the serration of the shift shaft you can adjust the footrest system optimally for th...

Page 126: ...00706 10 Remove the screw with the foot brake lever stub Position the foot brake lever stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tig...

Page 127: ...leased and the hex nut is locked 100708 10 Check the foot brake lever setting Info Position of the foot brake lever may vary considerably depending on the set ting 9 26 Checking free travel of foot br...

Page 128: ...lever 3 5 mm 0 12 0 2 in Info The piston rod should not move in the process If the free travel does not meet specifications Adjust the free travel 9 27 Checking for chain dirt 400678 01 Check the cha...

Page 129: ...mental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of th...

Page 130: ...k On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 700322...

Page 131: ...ine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission ca...

Page 132: ...reference marks The rear wheel is then correctly aligned Info The lower chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nu...

Page 133: ...procket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The eng...

Page 134: ...section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than...

Page 135: ...e the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining chassis screws M6 10 Nm 7 4 lbf...

Page 136: ...ront 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake discs x Check the brake discs for damage cracking and deformation If the brake discs exhibit damage c...

Page 137: ...f the brake disc thickness is less than the specified value Change the brake disc x Check the brake disc for damage cracking and deformation If damage cracks or deformation are visible on the brake di...

Page 138: ...and rear brakes according to the service schedule Your authorized KTM RC8 workshop will be pleased to help 100712 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position C...

Page 139: ...ake fluid of the front and rear brakes according to the service schedule Your authorized KTM RC8 workshop will be pleased to help Warning Environmental hazard Hazardous substances cause environmental...

Page 140: ...e entered in the homologation documents Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brak...

Page 141: ...d Change the front brake linings x Check all brake linings on both brake calipers for damage and cracking If damage or wear is encountered Change the front brake linings x 9 39 Checking the rear brake...

Page 142: ...heck the brake system and do not continue riding Your authorized KTM RC8 workshop will be pleased to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with sk...

Page 143: ...een brake fluid and painted parts Brake fluid is corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container 100717 10 Stand the vehicle upright Remove screw cap with...

Page 144: ...04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings x 9...

Page 145: ...push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake d...

Page 146: ...lace the wheel bearing x Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 239 100780 10 Insert the wide spacer on the left hand side when looking in the dire...

Page 147: ...00719 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws on both brake calipers but do not tighten yet Operate the hand brake lever repeatedly until the...

Page 148: ...nd compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Fork end pinch bolts M8 15 Nm 11 1 lbf ft 9 44 Removing the rear wheel x Jack up the motorcycle at t...

Page 149: ...refully without damaging the rim or brake disc Info Do not operate the foot brake when the rear wheel is removed 9 45 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency...

Page 150: ...is damaged or worn Replace the wheel bearing x Install the spacer Clean the thread of the axle and nut Clean the mating surfaces of the brake caliper frame and swingarm 100725 10 Push the brake calipe...

Page 151: ...ace it on the tensioning screw Tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the...

Page 152: ...is damaged or worn Change the shock absorber x Position the rear sprocket carrier Info A set of bolts and shock absorbers should have as little free play as possible to increase the service life of t...

Page 153: ...iding at alternating angles The full grip levels are not achieved until the tires have been run in Info The type condition and air pressure of the tires all have a major impact on the handling of the...

Page 154: ...latest after five years If a tire is more than five years old Change the tires 9 48 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire p...

Page 155: ...key in the seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards 9 50 Fitting the seat 100730 10 Position the recesses of the seat to the lugs on th...

Page 156: ...g Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up on the suppo...

Page 157: ...Guide the steel cable through the helmet opening Then position the free loop of the steel cable on the lug Position the helmet carefully on the side of the vehicle Fit the seat p 153 9 54 Removing th...

Page 158: ...nic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Switch off all power consumers and the engine Remove the seat p 153 100734 1...

Page 159: ...e screws Removing the securing bracket Pull the battery up and out of the battery rack 9 55 Installing the battery x 100737 10 Position the battery in the battery rack Info The terminals of the batter...

Page 160: ...en screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Reconnect the positive plus cable of the battery Position cover of the positive terminal 100734 11 Reconnect the negative minus cable o...

Page 161: ...nse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the en...

Page 162: ...scapes 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 d...

Page 163: ...id Charge the battery at no more than 10 of the capacity specified on the battery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and c...

Page 164: ...rs and the engine Remove the seat p 153 100739 10 Remove protection covers Remove the faulty main fuse Info A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 22...

Page 165: ...cal system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumer...

Page 166: ...icense plate lamp Fuse 3 10A horn brake light Fuse 4 10A radiator fan Fuse 5 10A fuel pump Fuse 6 10A ignition fuel injection Fuse 7 not used Fuse 8 10A for supplementary equipment standard accessorie...

Page 167: ...o reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consume...

Page 168: ...h off the retaining clamp on both sides squeeze and fold to the side Remove headlight bulb 700296 01 Position the new headlight bulb in the headlight housing Low beam high beam H7 base PX26d p 227 Inf...

Page 169: ...7 400422 10 Position the lug of the lamp cover in the notch Engage the latch Check that the lighting is functioning properly 100744 10 Position the rubber holder Fold down the combination instrument P...

Page 170: ...Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the...

Page 171: ...clamp on both sides squeeze and fold to the side Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam high beam H7 base PX26d p 227 Info Insert the headlight bulb so...

Page 172: ...lamp cover in the notch Engage the latch Check that the lighting is functioning properly 100745 11 Position the cover Info Check for correct positioning and freedom of movement of the brake lines Moun...

Page 173: ...or Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and th...

Page 174: ...r Remove the light bulb Position a new light bulb in the holder Parking light W5W base W2 1x9 5d p 227 Carefully position the holder with the bulb in the holder in the headlight 400422 12 Position the...

Page 175: ...wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at a distan...

Page 176: ...deline A motorcycle with rider including the luggage and a passenger where applicable the light cut off must be aligned exactly on the lower mark when checking headlight adjustment Info Turn clockwise...

Page 177: ...mobilizer indicator lamp lights up Switch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key Insert the black ignition key in the ignition l...

Page 178: ...ignition by turning the orange programming key to the OFF position Switch on the ignition by turning the orange programming key to the ON position EFI warning lamp MIL lights up switches off and then...

Page 179: ...g key to the position ON EFI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and switches on again Switch off the ignitio...

Page 180: ...better heat dissipation for the engine oil during the journey The pressure in the cooling system resulting from heat is regulated by a valve in the radi ator cap The heat expansion causes the surplus...

Page 181: ...water Condition The engine is cold The radiator is completely full 100750 01 Rest the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant...

Page 182: ...ctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reac...

Page 183: ...distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Tu...

Page 184: ...p 182 9 70 Correcting fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the h...

Page 185: ...st the play in the throttle cable x p 184 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure t...

Page 186: ...in the throttle cable by turning adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut Mount the protection cap 9 73 Handlebar height position 100755 10 Handlebar height B...

Page 187: ...andlebar position difference between and 6 5 Standard Position 9 74 Adjusting the handlebar height position Info The handlebar stub position must be identical on the left and right of the vehicle 1007...

Page 188: ...leeve above the triple clamp Mount and tighten screw Guideline Remaining frame bolts M5 5 Nm 3 7 lbf ft 100759 01 Tighten the screw Guideline Screw handlebar stub M8 20 Nm 14 8 lbf ft Repeat the adjus...

Page 189: ...100760 10 Remove screw with distance sleeve Carefully shift the handlebar stub by the length of the distance sleeve Watch out for the handlebar position difference Guideline Long distance sleeve 20 m...

Page 190: ...orrect the cable routing If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986 11 Adjus...

Page 191: ...o over the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986...

Page 192: ...handlebar stub Carefully move the handlebar to and fro over the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish fr...

Page 193: ...ide behavior Following modifications ride slowly at first to get the feel of the new ride behavior Remove the seat p 153 100762 10 Remove screws with the bushings 100763 10 Setting a higher seat posit...

Page 194: ...sides of the vehicle Push the rear end up until the drill holes of the frame are level with the lower rear drill holes of the rear Mount the screw and washer on the left and right sides of the vehicl...

Page 195: ...oles of the rear Mount the screw and washer on the left and right sides of the vehicle but do not tighten 100765 11 Remove screw with washer on the left and right sides of the vehicle Push the rear en...

Page 196: ...the rear left fixing screw the plug in cable binder is pushed out of the thread To reposition the cable of the lambda sensor fix the plug in cable binder in the remaining free drill hole Info Check t...

Page 197: ...oil level in the measurement range Info After switching off the engine wait one minute before checking the level The engine oil level must be in the middle of the measurement range of the oil dipstic...

Page 198: ...motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental...

Page 199: ...ake off the left exhaust cover 100772 10 Stand the motorcycle on its side stand on a level surface Place a suitable container under the engine Remove oil drain plug with the magnet O rings and oil scr...

Page 200: ...100773 10 Thoroughly clean magnet and oil screen of the oil drain plug 100772 11 Mount and tighten the oil drain plugs with the magnet O rings and oil screen Guideline Oil drain plug M20x1 5 20 Nm 14...

Page 201: ...ten screws Guideline Remaining frame bolts M5 5 Nm 3 7 lbf ft 9 80 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropri...

Page 202: ...e fluid etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100774 10 Remove screws Take off oil filter cover with the O ring 100775 10 Pull o...

Page 203: ...Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100777 10 The oil must be topped up in two steps Engine oil 3 60 l 3 8 qt Ex...

Page 204: ...an effective exhaust extraction system Start the engine and check that it is oil tight Remove the dipstick and pour in the remaining engine oil Engine oil 2nd quantity 0 60 l 0 63 qt External temperat...

Page 205: ...sults in premature wear to the engine Check the engine oil level p 195 100777 10 Remove the dipstick and add engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 236 Condition Ex...

Page 206: ...g them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective...

Page 207: ...er active Read the immobilizer blink code EFI control unit not activated Encode the EFI control unit x Malfunction in CAN bus communica tion Read out the trouble code memory using the KTM diagnostics...

Page 208: ...ode memory using the KTM diagnostics tool x Engine overheats HIGH TEMP Too little coolant in cooling system Check the cooling system for leaks x Check the coolant level p 179 Cooling fins very dirty C...

Page 209: ...light and horn do not work Fuse 3 blown Change the fuses of individual power consumers p 163 Battery discharged Ignition not switched off when vehicle parked Recharge the battery x p 159 Battery is n...

Page 210: ...ink code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink code of immo...

Page 211: ...indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 3...

Page 212: ...p MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code EFI warning lamp MIL 09 EFI war...

Page 213: ...too low Intake air temperature sensor input signal too high Blink code EFI warning lamp MIL 14 EFI warning lamp MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input sig...

Page 214: ...t Error level condition Power supply circuit fault Blink code EFI warning lamp MIL 25 EFI warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch circuit fault Blink code EFI...

Page 215: ...l condition Fuel pump relay short circuit to ground or open circuit Fuel pump controller input signal too high Blink code EFI warning lamp MIL 45 EFI warning lamp MIL flashes 4x long 5x short Error le...

Page 216: ...ode EFI warning lamp MIL 54 EFI warning lamp MIL flashes 5x long 4x short Error level condition Secondary air valve short circuit to ground or open circuit Secondary air valve input signal too high Bl...

Page 217: ...g lamp MIL 81 EFI warning lamp MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code EFI warning lamp MIL 91 EFI warning lamp MIL flashes 9x long 1x shor...

Page 218: ...in applicable regulations Info To maintain the value and appearance of the motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle Before cleaning seal the...

Page 219: ...of the engine and brakes After the engine has cooled down lubricate or grease all moving parts and bearings Clean the chain p 126 Treat bare metal except for brake discs and the exhaust system with a...

Page 220: ...has been used on salted roads clean it with cold water Warm water intensifies the effects of salt Clean the motorcycle p 216 Treat the engine swingarm and all other bare or galvanized parts except the...

Page 221: ...fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 216 Change the engine oil and filter clean the oil screen x p 195 Check the coolant level p 179 Check th...

Page 222: ...er vapor produced during combustion condenses and causes valves and exhaust system to rust 15 2 Putting into operation after storage Take the front of the motorcycle off the work stand p 100 Take the...

Page 223: ...30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston pin bearing No bearing bushes DLC coated piston pins Pi...

Page 224: ...W Spark plug NGK LKAR9BI9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 500 1 600 rpm Cold start device Electric...

Page 225: ...43 Remaining engine screws M6 10 Nm 7 4 lbf ft Screw camshaft bearing support M6 10 9 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Loctite 243 Screw...

Page 226: ...8 10 9 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw camshaft bearing support M8 10 9 Step 1 8 5 Nm 6 27 lbf ft Step 2 14 5 Nm 10 7 lbf ft Only applies when using Hex key bit 61229025000 Scre...

Page 227: ...Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 17 N...

Page 228: ...n floating disc with radial mount 4 piston calipers Rear Single non floating disc with 2 piston brake caliper Brake discs diameter Front 320 mm 12 6 in Rear 220 mm 8 66 in Brake discs wear limit Front...

Page 229: ...um permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 240 kg 529 lb Maximum permissible total weight 380 kg 838 lb Battery YTZ14S Battery voltage 12 V Nominal capacity 11 2 A...

Page 230: ...C 58W TL Pirelli Diabolo Supercorsa SP 190 55 ZR 17 M C 75W TL Pirelli Diabolo Supercorsa SP Additional information is available in the Service section under http www ktm com 18 3 Capacity fuel Total...

Page 231: ...t 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload space...

Page 232: ...ll payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full pay...

Page 233: ...TECHNICAL DATA SHOCK ABSORBER 231 Gas pressure 10 bar 145 psi Static sag 10 15 mm 0 39 0 59 in Riding sag 30 35 mm 1 18 1 38 in Inbuilt length 290 mm 11 42 in Shock absorber oil p 237 SAE 2 5...

Page 234: ...10 Nm 7 4 lbf ft Loctite 243 Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw for wheel speed sensor bracket M6 3 Nm 2 2 lbf ft Loctite 243 Screw exhaust...

Page 235: ...stub M8 20 Nm 14 8 lbf ft Screw ignition lock ratchet screw M8 Loctite 243 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw rear footrest bracket M8 25 Nm 18 4 lbf ft Screw shift lever M8...

Page 236: ...rew side stand M10 35 Nm 25 8 lbf ft Loctite 243 Rear sprocket bolt M10x1 25 50 Nm 36 9 lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Nut of bell crank on frame M...

Page 237: ...products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifree...

Page 238: ...responding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 241 SAE p 241 SAE 5W 40 Guideline Use o...

Page 239: ...fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM r...

Page 240: ...SUBSTANCES 238 Super unleaded ROZ 98 RON 98 PON 94 According to DIN EN 228 ROZ 98 RON 98 PON 94...

Page 241: ...be for road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex product...

Page 242: ...lier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal...

Page 243: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Page 244: ...ngs 138 front brake checking 138 rear brake checking 141 Brakes 93 Braking 93 C Chain checking 131 checking for dirt 126 cleaning 126 Chain tension adjusting 129 checking 128 Cleaning 216 217 Clutch f...

Page 245: ...e RACEODO 45 63 65 TPMS menu 60 64 66 TRIP F RESET menu 55 64 66 UNITS menu 56 64 66 Conservation for winter operation 218 Coolant level checking 179 Cooling system 178 filling compensating tank 180 E...

Page 246: ...asic position adjusting 135 Handlebar handlebar height 184 handlebar height adjusting 185 handlebar position 184 handlebar position adjusting 185 Headlight adjustment adjusting 174 checking 173 Headli...

Page 247: ...ing 201 removing 199 Oil screen cleaning 195 196 Owner s manual 11 P Parking 94 Parking light bulb changing 171 Passenger footrests 80 Passenger seat mounting 154 removing 154 Play in the throttle cab...

Page 248: ...amping high speed adjusting 107 compression damping low speed adjusting 106 rebound damping adjusting 108 spring preload adjusting 109 Shock absorber part number 18 Side stand 82 Spare parts 8 Startin...

Page 249: ...5 207 Turn signal switch 21 Type label 16 U Use definition 8 V Vehicle identification number 16 Vehicle level 113 front adjusting 114 rear adjusting 116 View of vehicle front left 12 rear right side 1...

Page 250: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 12 2009 Photo Mitterbauer 3211525en 3211525en...

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