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KTM 1190 RC8, Owner'S Manual, Page: 125 / 240

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KTM 1190 RC8 Owner'S Manual Download Page 125

MAINTENANCE WORK ON CHASSIS AND ENGINE

123

9.28

Checking the chain tension

Warning

Danger of accidents

 

Danger caused by incorrect chain tension.

–

If the chain tension is too high, the components of the secondary power train (chain, engine 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 can break. 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 for correct chain tension and adjust if necessary.

700322-01

–

Lean the motorcycle on the side stand.

–

Shift into neutral.

–

In the area in front of where the chain passes through the link fork, push the chain
upward and measure chain tension

.

Info

The lower chain section

must be taut.

Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.

Chain tension

15… 20 mm (0.59… 0.79 in)

» If the chain tension does not meet specifications:

–

Adjust the chain tension. (

p. 124)

Summary of Contents for 1190 RC8

Page 1: ...OWNER S MANUAL 2009 1190 RC8 EU UK 1190 RC8 AUS 1190 RC8 FR 1190 RC8 JP ART NO 3211373en ...

Page 2: ......

Page 3: ...g 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 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 condition...

Page 4: ...d 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 AG 5230 Mattighofen Austria ...

Page 5: ...lebar 25 Combination instrument activation and test 26 Display 27 Info display 28 Indicator lamps 29 Notes warnings on the combination instrument 30 Odometer menu ODO Trip 1 33 Odometer menu ODO Trip 2 34 FUELDISTANCE menu 35 FUELRANGE menu 36 DISTANCE TO Next Service menu 37 LAPSTOGO menu 38 TOPSPEED menu 39 LAP BESTLAP LastLap menu 40 LAP BESTLAP TopSpeed menu 41 Total distance menu in Race mode...

Page 6: ...KTM RC8 workshop 92 Important service tasks to be carried out by an authorized KTM RC8 workshop as additional job 95 MAINTENANCE WORK ON CHASSIS AND ENGINE 96 Jacking up motorcycle front 96 Taking front of motorcycle off work stand 96 Jacking up motorcycle rear 97 Taking rear of motorcycle off work stand 97 Fork shock absorber 98 Adjusting the compression damping of the fork 98 Adjusting the rebou...

Page 7: ...king tire air pressure 145 Removing the seat 146 Fitting the seat 146 Removing the passenger seat 147 Mounting the passenger seat 147 Mounting the helmet lock on the vehicle 148 Removing the battery x 148 Installing the battery x 150 Recharging the battery x 152 Changing the main fuse 154 Changing the fuses of individual power consumers 156 Changing the low beam bulb 158 Changing the high beam lam...

Page 8: ...onservation for winter operation 208 STORAGE 209 Storage 209 Putting into operation after storage 210 TECHNICAL DATA ENGINE 211 Capacity engine oil 212 Capacity coolant 212 TECHNICAL DATA ENGINE TIGHTENING TORQUES 213 TECHNICAL DATA CHASSIS 216 Lighting equipment 217 Capacity fuel 218 TECHNICAL DATA FORK 219 TECHNICAL DATA SHOCK ABSORBER 220 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 222 SUBSTANCES...

Page 9: ...cialist 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 trained experts with the necessary special tools Identifies a page reference more information is provided on the specified page Formats used The type formats used are explained here Specific name Ident...

Page 10: ...e worn parts before the wear limit shown in the service schedule is reached Pay special attention to the prescribed running in times inspection and maintenance intervals Proper compliance will contribute consid erably to a longer service life of your motorcycle Warranty The work described in the service schedule must be carried out exclusively in an authorized KTM RC8 workshop and confirmed in the...

Page 11: ...orthiness Transport Note Danger of damage The parked vehicle can roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components get very hot when the machine is driven Do not place the vehicle where there are flammable or explosive substances Do not place objects over the vehicle while it is still warm from being run Always let the vehicle cool ...

Page 12: ...easures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage 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 ...

Page 13: ...IMPORTANT NOTES 11 The owner s manual is an important component of the motorcycle and should be passed on to the new owner if the bike is sold ...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side 700243 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 700242 10 ...

Page 17: ...at 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 pedal 10 Engine number 11 Brake calipers front ...

Page 18: ...above the chassis 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 in a safe place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used for learning and programming functions ...

Page 19: ...N OF SERIAL NUMBERS 17 4 3 Engine number 700223 01 The engine number is stamped on the right side of the engine 4 4 Fork part number 700224 01 The fork part number is stamped on the inner side of the fork stub ...

Page 20: ...mber 700225 01 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 700226 01 The steering damper part number is stamped on the top of the steering damper ...

Page 21: ...1 The clutch lever is fitted on the left side of the handlebar The clutch is hydraulic and self adjusting 5 2 Hand brake lever 700228 01 The hand brake lever is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 22: ...t are switched on High beam on Light switch is turned upwards In this position the low beam the high beam and the tail light are switched on 5 4 Headlight flasher switch 700232 01 The headlight flasher switch is fitted on the left side of the handlebar Possible states Headlight flasher switch in neutral position Headlight flasher switch pressed The headlight flasher switch high beam is oper ated i...

Page 23: ...lly to the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use To switch off the flasher light press the flasher switch towards the switch case 5 6 Horn button 700230 11 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button p...

Page 24: ...gnition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The black ignition key can be removed 5 8 Emergency OFF switch 700229 11 The emergency OFF switch is installed on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation the ignition circuit is ...

Page 25: ...tarter button 700229 12 The electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in neutral position Electric starter button pressed In this position the electric starter is operated ...

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

Page 27: ...e MODE 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 Changes to the next item in the info display in ROAD mode Clocks the lap times in RACE mode ...

Page 28: ... segments 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 appears in the info display In ROAD mode the info display switches to ODO Trip 1 Time 1 Avs 1 mode In RACE mode the info display switches to LAPSTOGO LastLap Last Best mode ...

Page 29: ... rev excessive 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 time must be reset The coolant temperature is shown in degrees Celsius or Fahrenheit in segment The info display shows additional information ...

Page 30: ...g on public roads Menu 2 is RACE mode for riding on race courses It allows riders to time laps themselves If the general warning lamp lights up the corresponding message is shown periodically in the info display Information repeat 45 s The information shown in the info display can be controlled with the function buttons ...

Page 31: ...eached The idling speed indicator lamp lights up green The transmission is in neutral The high beam indicator lamp lights up blue The high beam is on EFI warning lamp MIL lights up flashes red The OBD has detected an emission or safety critical error The general warning lights up green An operating safety warning mes sage was detected This is also shown periodocally in the info display The immobil...

Page 32: ...instrument 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 falls below the specified value Battery voltage 10 80 V ...

Page 33: ...e 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 400469 01 FRONT SENSOR appears on the info display if the coolant temperature sensor of the front cylinder is defective ...

Page 34: ...oolant temperature between the coolant temperature sensors of the front and rear cylinders 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 value Temperature 3 C 37 F ICE switches off on the info display if the external temperature rises above the specified value Temperature 4 C 39...

Page 35: ...p to 9999 9 Time 1 shows the journey time on the basis of Trip 1 and resumes running as soon as a speed signal is received The calculation of this value starts with the first speed signal and ends 3 seconds after the last speed signal Avs 1 average speed is coupled with Trip 1 and Time 1 Press the button No function Press the button No function Press the button and the button for 3 5 seconds The d...

Page 36: ...p 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 received The calculation of this value starts with the first speed signal and ends 3 seconds after the last speed signal Avs 2 average speed is coupled with Trip 2 and Time 2 Press the button No function Press the button No function Press the button and the button for 3 5 seconds The d...

Page 37: ...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 off in the SET UP menu Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds No functio...

Page 38: ...nly after 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 fuel reserve depends on your riding style Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press ...

Page 39: ...til DISTANCE 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 button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds No function Press the MODE but ton briefly Next display mode ...

Page 40: ...e time is not running This function is controlled by the button LAP LastLap shows the lap time of the last round Last shows the difference between the last lap and the lap before last Best shows the difference between the last lap and the best lap If the last lap was the fastest you see behind Best the Best symbol in the info display Press the button No function Press the button No function Press ...

Page 41: ...ighest lap speed LastLap shows the maximum speed of the last round Last shows the maximum speed difference between the last lap and the lap before Best shows the maximum speed difference between the last lap and the highest maximum speed If the last lap was the lap with the highest maximum speed the info display shows Best Best Press the button No function Press the button No function Press the bu...

Page 42: ...r of the lap with the best lap time LastLap shows the time of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press the button The next lap is displayed Press the button The previous lap is displayed Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All values in RAC...

Page 43: ... 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 the button The next lap is displayed Press the button The previous lap is displayed Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All valu...

Page 44: ...overed 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 highest speed reached during the RaceTrip Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the...

Page 45: ... display 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 accessories Select EXIT SETUP to close the SET UP menu The symbol shows which menu you can activate with the button MODE Press the button The arrow moves up Press the button The arrow moves down...

Page 46: ...seconds 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 for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit CHANGE MODE Press the MODE but ton briefly Open and exit CHANGE MODE ...

Page 47: ...SET CLOCK 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 button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit SET CLOCK or change to next value Press the MODE but ton briefly Open and exit SET CLOCK or change to next v...

Page 48: ...et 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 Only a KTM RC8 workshop can make changes on the S LEARN TPMS menu On the BACK menu you can switch back to the SET UP menu The symbol shows which menu you can activate with the button MODE Press the button The arrow moves up Press the button The...

Page 49: ... 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 Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit SHIFT RPMS or change to the next value Press the MODE but ton briefly Open and exit SHI...

Page 50: ...he MODE button briefly Press the button once until the symbol is on 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 Press the button increases the value Press the button decreases the value Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit LAP BLANK T P...

Page 51: ...tton 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 Press the button increases the value Press the button decreases the value Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit SET NUM LAPS Pre...

Page 52: ... button three times until the symbol is on 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 changes of the fuel level Press the button increases the value Press the button decreases the value Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open an...

Page 53: ...r measuring 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 the button MODE Press the button The arrow moves up Press the button The arrow moves down Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds The ...

Page 54: ...ITS in 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 the button Changes the unit Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit SET KM MILES Press the MODE but ton briefly Open and e...

Page 55: ...s the MODE button briefly Press the button once until the symbol is on 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 the button Changes the unit Press the button Changes the unit Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit SET C F Press the MO...

Page 56: ...ck on off available as 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 can activate with the button MODE Press the button The arrow moves up Press the button The arrow moves down Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 ...

Page 57: ...MODE button briefly Press the MODE button briefly On the OPTION TPMS menu you can switch the tire pressure check on off available as accessory Press the button Switches the tire pressure display on off Press the button Switches the tire pressure display on off Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec onds Open and exit OPTION TPMS Press the MOD...

Page 58: ...until the symbol is on 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 external temperature display on off Press the button Switches the external temperature display on off Press the button and the button for 3 5 seconds no function Press the MODE but ton for 3 5 sec ond...

Page 59: ...hanges 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 No function The display changes to the SET UP menu No function Next display mode LAPSTOGO menu No function No function The display changes to the SET UP menu All values in RACE mode are reset ex...

Page 60: ...on The 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 SET CLOCK menu increases the value decreases the value no function Open and exit SET CLOCK or change to next value Open and exit SET CLOCK or change to next value SETTINGS menu The arrow moves up ...

Page 61: ...he menu 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 unit no function Open and exit SET C F Open and exit SET C F OPTIONS menu The arrow moves up The arrow moves down no function The menu in front of the arrow is selected The menu in front of the arro...

Page 62: ...y RACE 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 LAPSTOGO menu TOPSPEED menu LAP BESTLAP LastLap menu LAP BESTLAP TopSpeed menu Total distance menu in Race mode RACEODO SET UP menu CHANGE MODE menu SET CLOCK menu SETTINGS menu SHIFT RPMS menu LAP menu ...

Page 63: ...de The 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 MILES menu SET C F menu OPTIONS menu TPMS menu OUTERTEMP menu 5 41 Displaying lap times Condition The ignition is on The motorcycle is stationary RACE mode ...

Page 64: ...p is displayed Press the MODE button briefly Next display mode 5 42 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE mode 400447 01 Press the MODE button briefly and repeatedly until LAP BESTLAP TopSpeed appears in the info display LAP01 appears on the left of the info display Press the button The next lap is displayed Press the button The previous lap is dis...

Page 65: ...y changes to the SET UP menu Press the button briefly and repeatedly until the symbol is on EXIT SETUP in the info display Press the MODE button briefly 5 44 Setting the clock with SET CLOCK Condition The ignition is on The motorcycle is stationary 400455 01 Press the button and the button for 3 5 seconds Press the button once until the symbol is on SET CLOCK in the info display Press the MODE but...

Page 66: ...ignition is on The motorcycle is stationary 400460 01 Press the button and the button for 3 5 seconds Press the button twice until the symbol is on SETTINGS in the info display Press the MODE button briefly Press the MODE button briefly RPM1and RPM2 appear on the info display The engine speed after RPM1 flashes Info The engine speed can be set at intervals of 50 RPM1 is the engine speed above whic...

Page 67: ...utton Press the MODE button briefly The 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 is on BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol is on EXIT SETUP in the info display Press the MODE button briefl...

Page 68: ... 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 button Info LAP BLANK T can be set between 1 and 200 Press the MODE button briefly The settings are stored and the display changes to the SETTINGS menu Press the button briefly and repeatedly until the sy...

Page 69: ...tton 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 You can set TOTAL LAPS to between 1 and 99 laps Press the MODE button briefly The settings are stored and the display changes to the SETTINGS menu Press the button briefly and repeatedly until the symbol...

Page 70: ...RIPF 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 the button Info You can set the TRIPF RESET to between 10 and 1000 seconds in steps of 10 Press the MODE button briefly The settings are stored and the display changes to the SETTINGS menu Press the button briefly and ...

Page 71: ...lay 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 briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol is on BACK in the info display Press the MODE button briefly Press the button briefl...

Page 72: ...e 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 briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol is on BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol is on EX...

Page 73: ...utton 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 the display changes to the OPTIONS menu Press the button briefly and repeatedly until the symbol is on BACK in the info display Press the MODE button briefly Press the button briefly and repeate...

Page 74: ...TING ELEMENTS 72 5 52 Opening the filler cap 700235 01 Lift the cover of the filler cap and insert the ignition key in the lock Turn the ignition key clockwise until the filler cap opens Open the filler cap ...

Page 75: ... filler cap 700236 01 Close the filler cap Push down the filler cap slightly until the lock closes Remove the ignition key and close the cover 5 54 Supporting strap 700244 01 The supporting strap is provided for the passenger to hold on to ...

Page 76: ...OPERATING ELEMENTS 74 5 55 Seat lock 700245 01 The seat lock is behind the seat It can be locked with the ignition key 5 56 Tool set 700310 01 The tool set is in the storage compartment under the seat ...

Page 77: ...ics and vehicle operation by a fitted helmet lock or helmet 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 58 Passenger footrests 700247 01 The passenger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For oper...

Page 78: ...LEMENTS 76 5 59 Shift lever 700239 01 The shift lever is mounted on the left of the engine 700238 01 The gear positions can be seen in the picture The neutral or idle position is between the first and second gear ...

Page 79: ...the rear brake 5 61 Side stand 700258 01 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 The safety start system is active Side stand folded in This position is mandatory for all journeys The safety start sys tem is inactive ...

Page 80: ... rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristics due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a...

Page 81: ...lever p 130 Adjust the footbrake pedal p 121 Get used to handling the vehicle on an empty car park before making a longer trip Try also to ride as slowly as possible to get a better feeling for the motorcycle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not make any changes to the vehicle and use only KTM approved recommended parts Info Parts from ot...

Page 82: ...Unstable handling 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 accidents Destruction of luggage carrier system If the motorcycle is fitted with luggage cases note the manufacturer s specifications concerning the maximum payload Warning Danger of accid...

Page 83: ...baggage 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 weight and the axle loads Guideline Maximum permissible total weight 380 kg 838 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 240 kg 529 lb ...

Page 84: ...Guideline Every 1 000 km 621 4 mi Check the chain tension p 123 Clean the chain p 122 Check the tire condition p 143 Check the tire air pressure p 145 Check the brake fluid level of the front brake p 130 Check the rear brake fluid level p 134 Check the front brake linings p 133 Check the rear brake linings p 136 Check the brake system Check the coolant level p 173 Check the adjustment and smooth o...

Page 85: ...ath When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds ...

Page 86: ...open the throttle to start If you open the throttle during starting the engine management does not supply any fuel so the engine cannot start Press the starter for a maximum of 5 seconds without a break Wait at least 5 seconds before trying to start again This motorcycle is equipped with a safety start system The engine will only start if in neutral or if a gear is engaged when the clutch lever is...

Page 87: ...n 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 is at a standstill Warning Risk of injury The passenger must be able to sit securely on the passenger seat The passenger must hold on to the rider or supporting strap firmly and place his her feet o...

Page 88: ...as been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly War...

Page 89: ...the positions of the 6 forward gears see the illustration The neutral or idle position is between the first and second gear First gear is used for starting off or for steep inclines When you reach maximum speed after fully opening the throttle turn back the throttle to about 3 4 of its range This barely reduces vehicle speed but lowers fuel consump tion considerably Open the throttle only as far a...

Page 90: ...uced braking 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 spongy pressure point of front or rear brake Have the brake system checked in an authorized KTM RC8 workshop before continuing your journey Warning Danger of accidents Brake system failure If the foot brake pedal is not released the brak...

Page 91: ... the engine You then do not need to brake so much and the brakes do not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components get very ...

Page 92: ... 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 only Park the motorcycle on firm ground Swing the side stand to the front with your foot as far as it will go and lean the motorcycle onto it Lock the steering by moving the handlebar to the left pressing down the black ...

Page 93: ...has come into contact 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 motorcycle is equipped with a regulated catalyst Leaded fuel will destroy the catalyst You should therefore use unleaded fuel only 700321 01 Switch off engine Open the filler cap p 72 Fill the ...

Page 94: ...out the status request and fault memory with the KTM diagnos tics tool x Check bellows for tears and leaks and check the linkage of the throt tle valve spigot for freedom of movement x Check the cable harness of the throttle valve body for damage and cor rect routing x Check hoses of vacuum sensors SLS hoses and vent hoses for dam age correct routing and leaks x Check the fuel hose for damage corr...

Page 95: ...e routing x Check the headlight adjustment p 168 Check the functioning of the electrical equipment Check the fairing parts for damage and breakage x Check screws and nuts for tightness x Brakes Check the front brake linings p 133 Check the rear brake linings p 136 Check the front brake discs p 128 Check the rear brake disc p 129 Check the brake fluid level of the front brake p 130 Check the rear b...

Page 96: ...ck the tire air pressure p 145 Check the chain wear p 127 Check the rear sprocket engine sprocket chain sliding guard to ensure that they are tight x Check the rear sprocket engine sprocket for wear p 126 Check the chain tension p 123 Clean the chain p 122 Check chain sliding guard p 128 Check wheel bearings for play x Check the rear hub shock absorbers x p 143 K10N after 1 000 km 621 4 mi K75A ev...

Page 97: ...0A J1A J2A Completely service fork x Completely service shock absorber x Clean and grease the steering head bearing and sealing elements x Clean battery poles and treat with contact grease Change the coolant x K150A every 15 000 km 9 320 mi after every sporting use K300A every 30 000 km 18 640 mi J1A annually J2A every 2 years ...

Page 98: ...o the straight ahead position Align the work stand at the front with the adapters to the fork legs Work stand front 61029055300 Info Always jack up the rear of the motorcycle first Jack up the motorcycle at the front 9 2 Taking front of motorcycle off work stand Note Danger of damage The parked vehicle can roll away or fall over Always place the vehicle on a firm and even surface Secure the motorc...

Page 99: ... 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 rear of motorcycle off work stand Note Danger of damage The parked vehicle can roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the work...

Page 100: ...xcessive force to turn the adjusting screws against the stop and take the last perceptible click as the end position These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 6 Adjust...

Page 101: ...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 suspension damping 9 7 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior An optimally adjusted rebound damping brakes the springing ener...

Page 102: ...ing to the fork type Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 8 Adjusting the spring preload of the fork Info The spring preload defines the initial situation of the spring process of the fork An optimally adjusted spring preload is adapted to the ...

Page 103: ...the fork 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 preload Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work However you should also adjust the rebound damping when you...

Page 104: ...rately in the low and high speed range Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compres sion and not the riding speed of the motorcycle The low and high speed adjustment works for all areas 9 11 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The sh...

Page 105: ...ng to 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 counterclockwise to reduce suspension damping 9 12 Adjusting the high speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is ...

Page 106: ... to the shock absorber type Guideline Compression damping high speed Comfort 3 turns Standard 2 5 turns Sport 1 5 turns Full payload 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 13 Adjusting the rebound damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly...

Page 107: ...turn counterclockwise to reduce suspension damping 9 14 Adjusting the spring preload of the shock absorber x Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle s handling characteristics Following modifications ride slowly at first to get the feel of the new handling characteristics Info The spring preload defines the initial situation of the spring process on...

Page 108: ...t do not remove 700342 01 Turn the adjusting ring counterclockwise with the toolset wrench until the spring is completely relaxed Hook wrench 69012022000 Extension 60012060000 Turn the adjusting ring clockwise and tension it to the specified value Guideline Spring preload Comfort 6 mm 0 24 in Standard 6 mm 0 24 in Sport 8 mm 0 31 in Full payload 8 mm 0 31 in Info Turn clockwise to increase preload...

Page 109: ...to suit the manner of driving and the road conditions For high speeds an adjustment with high damping can be chosen in order to use the steering damping function optimally In slow tight bends intensive damping can negatively affect handling and steering precision so the damping should be set to low 9 16 Adjusting the steering damper Info The hydraulic steering damper stabilizes the steering if the...

Page 110: ...ions 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 steering damper during the journey After adjusting the steering damper check the steering for smooth operation making sure that the handlebar can be moved from extreme left to extreme right without ...

Page 111: ...he front by means 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 Upper triple clamp flush with 1st ring of fork legs 2 5 mm 0 098 in Upper triple clamp flush with 2nd ring of fork legs stan dard 5 mm 0 2 in The chassis height can be adjusted steplessly ...

Page 112: ...wly at first to get the feel of the new handling characteristics 700352 01 Loosen screws on the lower triple clamp Loosen screw on the upper triple clamp Loosen 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 the screws of both fork legs are loosened the...

Page 113: ...flush with 2nd ring of fork legs standard 5 mm 0 2 in Info The standard adjustment is the setting that provides the best vehicle handling When the fork is compressed the chassis setting changes causing the vehicle to become more stable but also more difficult to handle 700352 10 Tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M...

Page 114: ...egs must be identical on both fork legs 9 19 Adjusting the vehicle level at the rear Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle s handling characteristics Following modifications ride slowly at first to get the feel of the new handling characteristics 700331 01 Loosen screw but do not remove it ...

Page 115: ...ion using the tool from the tool set Guideline Standard LOW Maximum adjustment range between HIGH LOW 180 Open end wrench SW 38 69012021000 Info The chassis height can be adjusted in both directions 700334 01 Tighten screw Guideline Screw clamp eccentric shaft of deflec tor M8 18 Nm 13 3 lbf ft ...

Page 116: ...ht and an individual adjustment of the operating elements The lower footrest position enables a more comfortable knee angle the upper footrest posi tion a sporting sitting position and more forward leaning freedom for use in racing 9 21 Adjusting footrest position Info The footrest position must be identical on the left and the right 700307 01 Remove screws ...

Page 117: ...table footrest bracket enables a more comfortable lower footrest posi tion or a sporting upper footrest position 700306 01 Mount and tighten screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 700309 01 Repeat adjustment work on the footrest bracket on the other side Adjust the shift lever p 116 Adjust the footbrake pedal p 121 ...

Page 118: ...he 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 243 9 23 Adjusting shift lever Info The footrest system offers many ways of adjusting the shift lever to your riding style and requirements ...

Page 119: ...115 130 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 central and aligned identically to each other in order to ensure freedom of movement in the bearing shells At least 5 screw threads must be screwed into the seating Tighten the counter nuts ...

Page 120: ...the 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 drill hole Shift power high short shift travel Shift lever upper drill hole shift shaft lower drill hole Position the shift rod Tighten the screws Guideline Screw shift rod M6 12 Nm 8 9 lbf ft Loctit...

Page 121: ...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 the upper footrest position After adjusting the shift lever conduct a function test There must be a minimum dis tance between the moving parts of the shift lever and other parts of the vehicle Guideline...

Page 122: ...ub 700305 01 Remove the screw with the footbrake pedal stub Position the footbrake pedal stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tighten screw Guideline Screw footbrake pedal stub M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 123: ... The range of adjustment is limited Remove the tool The spring tension on the anti rotation lock is released and the hex nut is locked 700346 01 Check the footbrake pedal setting Info Position of the shift lever can vary considerably depending on the setting 9 26 Checking for chain dirt Check the chain for loose dirt If the chain is very dirty Clean the chain p 122 ...

Page 124: ...ee of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The service life of the chain depends largely on its maintenance Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove o...

Page 125: ...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 for correct chain tension and adjust if necessary 700322 01 Lean the motorcycle on the side stand Shift into neutral In the area in front of where the chain passes through the link fork push the chain upward and measure chain tension Info The lower ch...

Page 126: ...e 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 can break 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 for correct chain tension and adjust if neces...

Page 127: ...e 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 nuts Make sure that the chain adjusters are on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of the chain ad...

Page 128: ...for wear 100132 10 Check the rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Change the rear sprocket engine sprocket chain and chain sliding guard x Info The rear sprocket engine sprocket chain and chain sliding guard should always be changed together ...

Page 129: ...t 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 the distance is greater than the specified measurement Change the rear sprocket engine sprocket chain and chain sliding guard x Info New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint Always have the chain c...

Page 130: ...king the front brake discs Warning Danger of accidents Reduced braking effect caused by worn brake discs Have worn brake discs replaced immediately in an authorized KTM RC8 workshop 100135 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4 0 mm ...

Page 131: ... discs replaced immediately in an authorized KTM RC8 workshop 400480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake linings Brake disc wear limit Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake disc x Check the brake disc for da...

Page 132: ...e fluid level of front brake Warning Danger of accidents Failure of brake system If the brake fluid level falls below the MIN mark there may be a leak in the brake system or the brake linings are completely worn out Have the brake system checked in an authorized KTM RC8 workshop before continuing your journey Warning Danger of accidents Reduced braking effect caused by old brake fluid Have the bra...

Page 133: ...e a leak in the brake system or the brake linings are completely worn out Have the brake system checked in an authorized KTM RC8 workshop before continuing your journey Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor im...

Page 134: ...ntact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 700262 01 Loosen screw Remove cover with membrane Top up the brake fluid to MAX level Brake fluid DOT 4 DOT 5 1 p 225 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 38 Brake linings The bra...

Page 135: ...o longer valid 9 39 Checking the front brake linings Warning Danger of accidents Reduced braking caused by worn brake linings Have worn brake linings replaced immediately in an authorized KTM RC8 workshop Note Danger of accidents Reduced braking due to damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is grea...

Page 136: ... old brake fluid Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM RC8 workshop 700264 01 Stand the vehicle upright Check the brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN mark Top up the rear brake fluid x p 134 9 41 Topping up rear brake fluid x Warning Danger of accidents Failure of brake system If th...

Page 137: ...ning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks ...

Page 138: ...hanged in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed 700266 01 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 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 th...

Page 139: ...ne side Info Do not pull the handbrake lever when the brake calipers are removed 700272 10 Loosen screws and Unscrew screw about 6 turns press your hand on the screw to push the wheel spin dle out of the fork stub Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the fr...

Page 140: ...osition it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft 700271 12 Position the brake calipers and check that the brake linings are seated correctly Mount and tighten screws Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Operate the hand brake lever several times until the brake pads are lying correctl...

Page 141: ...e and compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 9 45 Removing rear wheel x Jack up the motorcycle rear end p 97 700311 01 Remove nut Remove chain adjuster Withdraw the wheel spindle ...

Page 142: ... dam aged Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 9 46 Installing the rear wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger...

Page 143: ...shings Clean the thread of the wheel spindle and nut Clean the contact areas of the brake caliper support and swingarm 700314 01 Push the brake caliper support completely to the rear Position the rear wheel and position the brake caliper support between the rim and the brake disc Position the brake caliper on the brake disc Position the rear wheel on the bearing surfaces in the swingarm ...

Page 144: ... place 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 reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point ...

Page 145: ...bsorbers are damaged or worn Change the shock absorber x Position the rear sprocket carrier Info A set of bolts and shock absorbers with as little free play as possible increases the service life of the shock absorbers Install the rear wheel x p 140 9 48 Checking the tire condition Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire For your own safety have damaged t...

Page 146: ...s 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Info The type condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 400602 10 Check the front and rear tire for cuts penetrations and other damag...

Page 147: ...ire service life 700268 01 Remove dust cap Check tire air pressure when tires are cold Tire air pressure Solo Front 2 5 bar 36 psi Rear 2 5 bar 36 psi Tire air pressure with passenger full payload Front 2 5 bar 36 psi Rear 2 9 bar 42 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap Info The rubber seal in the dust cap prevents air leaking out of the tire i...

Page 148: ...of the seat push it towards the rear and remove it upwards 9 51 Fitting the seat 700269 01 Position the recesses of the seat to the lugs on the frame lower the rear end and simul taneously push it forward Lock the seat by turning the ignition key in the seat lock Remove the ignition key from the seat lock Finally check that the seat is correctly mounted ...

Page 149: ...ing 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 supporting strap There should be no play in the unlocking lever Position the passenger seat in the space provided Press down the passenger seat until it clicks into place Finally check that the passenger...

Page 150: ... 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 motorcycle Fit the seat p 146 9 55 Removing the battery x 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...

Page 151: ...GINE 149 Switch off all power consumers and switch off the engine Remove the seat p 146 700276 10 Disconnect the negative minus cable of the battery 700277 10 Remove the plus pole cover Disconnect the positive plus cable of the battery ...

Page 152: ...r operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety equipment can be damaged The vehicle is then no longer safe to ride 9 56 Installing the battery x 700279 01 Position the battery in the battery rack Info The poles of the battery must face the rear of the vehicle Position the bracket ...

Page 153: ...277 11 Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Reconnect the positive plus cable of the battery Position positive terminal cover 700276 11 Reconnect the negative minus cable of the battery Fit the seat p 146 ...

Page 154: ...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 Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Enviro...

Page 155: ...electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery becomes discharged from starting it must be recharged immediately If the battery rests for an extended time in a discharged state it becomes over discharged and sulfated which will result in its destruction The battery is maintenance free i e the acid level does not have to be checked Switch off all...

Page 156: ...ever remove the lid Charge the battery according to the instructions on the battery casing After charging the battery switch off the battery charger Reconnect 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 Fit the seat p 146 9 58 Changing the main fuse Warning Fire hazard The elect...

Page 157: ...ff the engine Remove the seat p 146 700280 01 Remove protection covers Remove a defective main fuse with a needle nose plier Info A reserve fuse is located in the starter relay Fit a new main fuse Fuse 58011109130 p 217 Info If the new fuse burns out after it is inserted it is important that you contact an authorized KTM RC8 workshop Attach the protection covers Fit the seat p 146 ...

Page 158: ... 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 consumers is located under the seat Switch off all power consumers and switch off the engine Remove the seat p 146 700281 01 Open fuse box cover ...

Page 159: ...zer alarm system optional Fuse 2 15A high beam low beam parking light tail light license 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 accessories Fuse 9 10A for supplementary equipment accessories connected to the ignition switch Fuse 10 not used Fuse SPARE 10A ...

Page 160: ...KTM RC8 workshop Tip Replace the spare fuse in the fuse box so that it is available if needed Close the fuse box cover Fit the seat p 146 9 60 Changing the low beam bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector Switch off all power c...

Page 161: ...ombination instrument Pull the lug out of the rubber holder Remove the rubber holder 700294 01 Release the latch Remove the lamp cover 700295 01 Disconnect plug in connector Push off the retaining clamp on both sides squeeze and fold to the side Remove headlight bulb ...

Page 162: ...in the headlight housing Low beam high beam H7 p 217 Info Insert the headlight bulb so that the lug is positioned in the cut out Position the retaining clamp Position the plug in connector 400422 10 Position the lug of the lamp cover in the notch Engage the latch Check lighting function ...

Page 163: ... the lug in the rubber holder 9 61 Changing the high beam lamp Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector Switch off all power consumers and switch off the engine ...

Page 164: ...MAINTENANCE WORK ON CHASSIS AND ENGINE 162 700297 01 Remove screws Remove cover 700298 01 Release the latch Remove the lamp cover ...

Page 165: ...taining 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 p 217 Info Insert the headlight bulb so that the lug is positioned in the cut out Position the retaining clamp Position the plug in connector ...

Page 166: ... the lug of the lamp cover in the notch Engage the latch Check lighting function 700335 10 Position cover Info Check for correct positioning and freedom of movement of the brake lines Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 167: ...e to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector Switch off all power consumers and switch off the engine 700297 01 Remove screws Remove cover ...

Page 168: ...e the latch Remove the lamp cover 700300 01 Pull the parking light carefully out of the holder Remove the light bulb Position a new light bulb in the holder Parking light W2 1x9 5d p 217 Carefully position the holder with the bulb in the holder in the headlight ...

Page 169: ... the lug of the lamp cover in the notch Engage the latch Check lighting function 700335 11 Position cover Info Check for correct positioning and freedom of movement of the brake lines Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 170: ... Guideline Distance 5 cm 2 in Stand the motorcycle at distance in from of the wall and switch on the ignition and the low beam Guideline Distance 5 m 16 ft Check the headlight adjustment The border between light and dark must be exactly at mark when the motorcycle is operational and complete with rider If the boundary between light and dark does not meet specifications Adjust the headlamp range p ...

Page 171: ... deactivated using the orange programming key You can activate or deactivate up to four black ignition keys Only the black ignition keys trained during an activation procedure are valid All black ignition keys not trained in the activation procedure are invalid but can be retrained in a further activation proce dure 700234 10 Loss of a black ignition key second black ignition key available Press t...

Page 172: ... lamp lights up switches off briefly and flashes according to the number of functioning black ignition keys including the orange programming key In this case twice Switch off the ignition by turning the orange programming key to the position Pull out the orange programming key The lost black ignition key is deactivated The existing black ignition key is reactivated Loss of both black ignition keys...

Page 173: ...the KEYCODECARD and activate it Activating ignition key Press the emergency OFF switch into the position Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the position EFI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up Switch off the ignition by turning the orange program...

Page 174: ...ition by turning the orange programming key to the position Pull out the orange programming key All black ignition keys are activated included in this job sequence are activated 9 66 Cooling system 400415 10 The water pump with a 3D water pump wheel in the engine ensures forced circulation of the coolant The heat exchanger enables faster warming of the engine oil at the start of a journey and bett...

Page 175: ...ffect 9 67 Checking the coolant level Warning Scalding hazard During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other components of the cooling system when the engine is hot Allow the engine and radiator to cool down If you are scalded hold the affected part under cold water immediately Condition The engine is cold Rest the m...

Page 176: ...k Warning Scalding hazard During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other components of the cooling system when the engine is hot Allow the engine and radiator to cool down If you are scalded hold the affected part under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoi...

Page 177: ...lled without air bubbles Air in the cooling system can lead to engine fail ure Have the coolant changed by an authorized KTM RC8 workshop 700324 01 Check the coolant level p 173 Remove the cap of the compensating tank Top up with coolant until the specified coolant level is reached Guideline The coolant level must be between MIN and MAX Alternative 1 Coolant p 225 Alternative 2 Coolant mixed ready...

Page 178: ...e handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 9 70 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake ...

Page 179: ...clutch p 177 9 71 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 handlebar to a horizontal position 700284 01 Remove screw cover with membrane Correct the fuel level Guideline The fluid level must be between the MIN and MAX markings Hydraulic fluid 15 p 227 Re...

Page 180: ...Bowden cable with adjusting screw Guideline Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 73 Handlebar height 700319 12 By removing or inserting the spacing sleeves you can set the handlebar height at two different positions Long distance sleeve 15 mm 0 59 in With distance sleeves the handlebar stub is positioned low for sports use Removing the distance sleeves gives a more upr...

Page 181: ...w Info Loosen the screw several turns to prevent damage to the fork lacquer when moving the handlebar stub Remove screw 700319 01 Remove distance sleeve All cables routed under the upper triple clamp must now be routed under the han dlebar stub Push the handlebar stub carefully up to the upper triple clamp Position the distance sleeve above the triple clamp Mount and tighten the screw Guideline Re...

Page 182: ...t of the steering Correct the cable routing 700320 11 Adjusting the low position of the handlebar stubs Loosen screw Info Loosen the screw several turns to prevent damage to the fork lacquer when moving the handlebar stub 700319 11 Remove screw with distance sleeve Carefully shift the handlebar stub by the length of the distance sleeve Guideline Long distance sleeve 15 mm 0 59 in Lay all cables be...

Page 183: ...epeat the adjustments on the other handlebar stub Move the handlebar to and fro over the entire steering range If the cables restrict the freedom of movement of the steering Correct the cable routing 9 75 Rear frame position 400439 10 The frame rear height can be set to two different positions enabling ergonomic adjustment of the seat height Seat height standard 805 mm 31 69 in Seat height 825 mm ...

Page 184: ...eristics Following modifications ride slowly at first to get the feel of the new handling characteristics Remove the seat p 146 700363 01 Remove screws with the bushings 700327 10 Setting a higher seat position Remove screw with washer on the left and right sides of the vehicle Push the rear end down until the drill holes of the frame are level with the lower front drill holes of the rear ...

Page 185: ...ht 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 vehicle and tighten Guideline Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 700330 01 Tighten screw on the left and right sides of the vehicle Guideline Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 ...

Page 186: ... holes of the rear Mount the screw and washer on the left and right sides of the vehicle but do not tighten 700327 14 Remove screw with washer on the left and right sides of the vehicle Push the rear end up until the drill holes of the frame are level with the upper front drill holes of the rear 700329 01 Mount the screw and washer on the left and right sides of the vehicle and tighten Guideline S...

Page 187: ...frame M8 20 Nm 14 8 lbf ft Loctite 243 700338 01 When you screw in the rear left fixing screw the plug in cable binder is pushed out of the thread To reposition the cable of the lambda probe fix the plug in cable binder in the remaining free drill hole Info Check the cable routing The cable of the lambda probe should not be taut ...

Page 188: ...d at normal engine operating temperature Stand the motorcycle upright on a horizontal surface 700301 10 Remove oil dipstick Check the engine 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 dipstick If the engine oil level is outside the specified range Add...

Page 189: ... Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Dr...

Page 190: ...ake off the left exhaust cover 700287 01 Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove oil drain plug with the magnet O rings and oil screen Remove the oil filter x p 190 Completely drain the engine oil ...

Page 191: ... 700292 01 Thoroughly clean the magnet and oil screen of the oil drain plug 700288 01 Mount and tighten the oil drain plugs with the magnet O rings and oil screen Guideline Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Install the oil filter x p 192 ...

Page 192: ... screws Guideline Remaining chassis screws 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 motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately ...

Page 193: ... cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine 700289 01 Remove screws Take off oil filter cover with the O ring 700290 01 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 ...

Page 194: ...ghten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 9 82 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 700301 01 The oil must be topped up in two steps Engine oil 3 60 l 3 8 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 226 External temperature 0 C 32 F Engine oil SAE 5W 40 p 226 ...

Page 195: ... poisonous and can 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 a closed space without 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 temperature 0 C ...

Page 196: ...ys make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 186 9 83 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine Check the engine oil level p 186 ...

Page 197: ...engine oil do not mix different types of engine oil If appropriate change the engine oil Replace oil dipstick Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space without an effective exhaust extraction system Start the engin...

Page 198: ...t not activated Activate the EFI control unit x Malfunction of CAN Bus communica tion Check the CAN Bus communication x Combination instrument defective Check the combination instrument x Engine cranks only if the clutch lever is pulled A gear is engaged Shift into neutral Safety start system defective Check the safety start system x Engine cranks although it is in gear Safety start system defecti...

Page 199: ...ge the coolant hose x Thermostat defective Check the thermostat x Fuse 4 blown Change the fuses of individual power consumers p 156 Defect in radiator fan system Check the radiator fan system x Air in cooling system Add coolant bleed the cooling system x EFI warning lamp MIL lights up flashes Fault in fuel injection system Read out the fault memory with the KTM diag nostics tool x Engine dies duri...

Page 200: ...f when vehicle parked Recharge the battery x p 152 Battery is not charged by the generator Check charging voltage x Combination instrument shows nothing in display Fuse 1 blown Change the fuses of individual power consumers p 156 Speedometer in combination instru ment doesn t work Wiring harness of wheel reveolution counter damaged or plug in connector oxidized Check the wheel speed sensor ...

Page 201: ...mp flashes 1x short 1 second pause 4x short Possible cause Malfunction in transponder of black ignition key Flash code of immobilizer indica tor lamp 15 Immobilizer indicator lamp flashes 1x short 1 second pause 5x short Possible cause Black ignition key inactive Flash code of immobilizer indica tor lamp 16 Immobilizer indicator lamp flashes 1x short 1 second pause 6x short Possible cause Malfunct...

Page 202: ...nction encryption query from EFI control unit to immobilizer control unit Flash code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pause 2x short Possible cause Malfunction of CAN Bus communication Flash code of immobilizer indica tor lamp 60 Immobilizer indicator lamp flashes 6x short Possible cause E PROM malfunction ...

Page 203: ...IL flashes 7x short Possible cause Input signal of throttle valve position sensor circuit B too low Input signal of throttle valve position sensor circuit B too high Flash code EFI Warning lamp MIL 09 EFI Warning lamp MIL flashes 9x short Possible cause Input signal from pressure sensor induction manifold cylinder 1 too low Input signal from pressure sensor induction manifold cylinder 1 too high F...

Page 204: ...oo high Flash code EFI Warning lamp MIL 15 EFI Warning lamp MIL flashes 1x long 5x short Possible cause Input signal from roll angle sensor too low Input signal from roll angle sensor too high Flash code EFI Warning lamp MIL 17 EFI Warning lamp MIL flashes 1x long 7x short Possible cause Malfunction in lambda probe circuit cylinder 1 Flash code EFI Warning lamp MIL 18 EFI Warning lamp MIL flashes ...

Page 205: ... long 4x short Possible cause Malfunction in injection valve circuit cylinder 2 Flash code EFI Warning lamp MIL 37 EFI Warning lamp MIL flashes 3x long 7x short Possible cause Malfunction in ignition coil circuit cylinder 1 Flash code EFI Warning lamp MIL 38 EFI Warning lamp MIL flashes 3x long 8x short Possible cause Malfunction in ignition coil circuit cylinder 2 Flash code EFI Warning lamp MIL ...

Page 206: ...o plus in lambda probe heating circuit cylinder 2 Flash code EFI Warning lamp MIL 49 EFI Warning lamp MIL flashes 4x long 9x short Possible cause Malfunction in idling control system circuit Flash code EFI Warning lamp MIL 50 EFI Warning lamp MIL flashes 5x long Possible cause Malfunction in throttle valve stepper circuit circuit B Flash code EFI Warning lamp MIL 54 EFI Warning lamp MIL flashes 5x...

Page 207: ... sensor induction manifold cylinder 1 leaky Flash code EFI Warning lamp MIL 69 EFI Warning lamp MIL flashes 6x long 9x short Possible cause Connection of pressure sensor induction manifold cylinder 2 leaky Flash code EFI Warning lamp MIL 72 EFI Warning lamp MIL flashes 7x long 2x short Possible cause Malfunction of throttle valve stepper circuit B Flash code EFI Warning lamp MIL 91 EFI Warning lam...

Page 208: ...cording to 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 exhaust system to prevent water from entering Remove loose dirt first with a soft jet of water Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Motorcyc...

Page 209: ...ate from inaccessible parts of the engine and brakes After the engine has cooled down lubricate or grease all moving parts and bearings Clean the chain p 122 Treat bare metal except for brake discs and the exhaust system with an anticorrosive Cleaning and polishing materials for metal rubber and plastic p 229 Treat all painted parts with a mild lacquer care spray High luster polish for paint p 229...

Page 210: ... has been used on salted roads clean it with cold water Warm water intensifies the effects of salt Clean the motorcycle p 206 Treat the engine swingarm and all other bare or galvanized parts except the brake discs with a wax based anticorrosive Info Avoid getting anticorrosive on the brake discs this would badly affect the braking After riding on salted roads thoroughly wash the motorcycle with co...

Page 211: ...as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 206 Change the engine oil and filter clean the oil screen x p 187 Check the coolant level p 173 Check the antifreeze x Check the tire air pressure p 145 Remove the battery x p 148 Recharge the battery x p 152 Guideline Storage temperature of battery without direct sunshine 0 3...

Page 212: ... up properly the water 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 96 Take the rear of the motorcycle off the work stand p 97 Recharge the battery x p 152 Install the battery x p 150 Set the clock with SET CLOCK p 63 Fill up with fuel p 90 Make checks before p...

Page 213: ...5 0 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 Piston Forged light alloy Piston ring 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 40 76 C...

Page 214: ... V 390 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 Cold start device Electric starter 16 1 Capacity engine oil Engine oil 3 60 l 3 8 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 226 External temperature 0 C 32 F Engine oil SAE 5W 40 p 226 16 2 Capacity coolant Coolant 2 60 l 2 75 qt Co...

Page 215: ...w clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Loctite 243 Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw engine housing M6x60 10 Nm 7 4 lbf ft Screw engine housing M6x80 10 Nm 7 4 lbf ft Screw engine housing M6x90 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel ring M6 13 Nm 9 6 lbf ft Loctite 648 Screw gener...

Page 216: ...ort M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw camshaft bearing support M8 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 Screw engine console M8 20 Nm 14 8 lbf ft Loctite 243 Screw engine housing M8 18 Nm 13 3 lbf ft Screw heat exchanger M8 15 Nm 11 1 lbf ft Screw timing chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw ti...

Page 217: ...5 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 12 Nm 8 9 lbf ft Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Nut inner clutch hub M22x1 5 130 Nm 95 9 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw in generator cover M24x1...

Page 218: ...isc brake with radially screwed four piston brake calipers float mounted brake discs Rear Single disc brake with dual piston brake caliper rigid mounted brake disc Brake discs diameter Front 320 mm 12 6 in Rear 220 mm 8 66 in Brake discs wear limit Front 4 0 mm 0 157 in Brake disc wear limit Rear 4 5 mm 0 177 in Tire air pressure Solo Front 2 5 bar 36 psi Rear 2 5 bar 36 psi Tire air pressure with...

Page 219: ...4 33 in Weight without fuel approx 184 kg 406 lb Maximum 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 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 18 1 Lighting equipment Low beam high beam H7 12 V 55 W Parking...

Page 220: ...70 ZR 17 M C 58W TL Pirelli Dragon Supercorsa Pro 190 55 ZR 17 M C 75W TL Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under http www ktm com 18 2 Capacity fuel Total fuel tank capacity approx 16 5 l 4 36 US gal Super unleaded ROZ 95 RON 95 PON 91 p 228 Fuel reserve approx 3 5 l 3 7 qt ...

Page 221: ...5 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 spacer s 405 mm 15 94 in Spring rate Weight of rider 75 85 kg 165 187 lb 9 5 N mm 54 2 lb in Air chamber length 80 20 10 mm 3 15 0 79 0 39 in Fork length 735 mm 28 94 in Fork oil 520 ml 17 58 fl oz Fork oil S...

Page 222: ...d 1 5 turns 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 payload 10 clicks Spring preload Comfort 6 mm 0 24 in Standard 6 mm 0 24 in Sport 8 mm 0 31 in Full payload 8 mm 0 31 in Spring rate Weight of rider 75 85 kg 165 187 lb 95 N mm 542 lb in Spring length 160 mm 6...

Page 223: ...TECHNICAL DATA SHOCK ABSORBER 221 Gas pressure 10 bar 145 psi Static sag 15 mm 0 59 in Riding sag 30 mm 1 18 in Inbuilt length 290 mm 11 42 in Shock absorber oil p 227 SAE 2 5 ...

Page 224: ... Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw exhaust clamp M6 8 Nm 5 9 lbf ft Screw exhaust heat shield M6 15 Nm 11 1 lbf ft Screw foot brake pedal M6 15 Nm 11 1 lbf ft Loctite 243 Screw footbrake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw footbrake pedal stub M6 10 Nm 7 4 lbf ft Loctite 243 Screw fuel pump M6 6 Nm 4 4 lbf ft Screw shift lever stub M6 10 Nm 7 4 lbf ft Loc...

Page 225: ...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 25 Nm 18 4 lbf ft Loctite 243 Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 15 Nm 11 1 lbf ft Loctite 243 Screw steering damper clamp on con sole M8 20 Nm 14 8 lbf ft Loctite 243 Screw steering damper fi...

Page 226: ...5 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 M14x1 5 100 Nm 73 8 lbf ft Lambda probe M18x1 5 45 Nm 33 2 lbf ft Nut swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw seat lock M22x1 5 8 Nm 5 9 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread grea...

Page 227: ...otorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant in countries with high temperatures also Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 Corrosion antifreeze 50 Distilled water Coolant mixed ready to use Ant...

Page 228: ...rresponding 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 231 SAE p 231 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplie...

Page 229: ...ic 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 recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 231 SAE 2 5 Guideline Use only oils that comply with the specified standards ...

Page 230: ...SUBSTANCES 228 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 231: ... and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Specification KTM recommends Motorex products Supplier Motorex Fett 2000 ...

Page 232: ...ecommends Motorex products Supplier Motorex Moto Clean 900 Onroad chain spray Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Universal oil spray Specification KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 233: ...ce 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 the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 234: ...for dirt 121 checking for wear 127 cleaning 122 Chain sliding guard checking 128 Chain tension adjusting 124 checking 123 Chassis number 16 Cleaning 206 207 Clutch fluid level checking 176 fluid level correcting 177 Clutch lever 19 adjusting basic position 176 Combination instrument activation and test 26 CHANGE MODE menu 44 58 60 display 27 DISTANCE TO Next Service menu 37 57 60 FUELDISTANCEmenu ...

Page 235: ...9 61 TRIP F RESET menu 50 59 61 UNITS menu 51 59 61 Conservation for winter operation 208 Coolant level checking 173 Cooling system 172 filling compensating tank 174 E Electric starter button 23 Emergency OFF switch 22 Engine running in 79 Engine number 17 Engine oil adding 194 changing 187 draining 187 refilling 192 Engine oil level checking 186 Environment 9 External temperature display switchin...

Page 236: ...and brake lever 19 adjusting basic position 130 Handlebar height 178 adjusting 179 Headlight adjustment adjusting 168 checking 168 Headlight flasher switch 20 Helmet lock 75 mounting on vehicle 148 High beam bulb changing 161 Horn button 21 I Ignition key activating deactivating 169 Ignition lock 22 K Key number 16 Kilometers miles SET KM MILES setting 69 L Lap times displaying 61 Light switch 20 ...

Page 237: ...ics 10 P Parking 89 Parking light bulb changing 165 Passenger footrests 75 Passenger seat mounting 147 removing 147 Play in gas Bowden cable adjusting 178 Putting into operation advice on first use 78 after storage 210 checks to be made before putting into operation 82 R RACE mode setting 63 Rear frame position 181 adjusting 182 Rear hub shock absorber checking 143 Rear sprocket engine sprocket ch...

Page 238: ...justing 102 rebound damping adjusting 104 spring preload adjusting 105 Shock absorber part number 18 Side stand 77 Spare parts accessories 8 Starting 83 Steering damper 107 adjusting 107 Steering damper part number 18 Steering lock 22 Stopping 89 Storage 209 Supporting strap 73 T Technical data chassis 216 218 chassis tightening torques 222 224 engine 211 212 engine tightening torques 213 215 fork...

Page 239: ...INDEX 237 V Vehicle level 109 front adjusting 110 rear adjusting 112 View of vehicle front left 12 rear right 14 W Warranty 8 Work rules 9 ...

Page 240: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2008 Photo Mitterbauer 3211373en 3211373en ...

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