KTM 2008 1190 RC8 USA Page 164 Owner'S Manual Download

Page: 164 / 247

MAINTENANCE WORK ON CHASSIS AND ENGINE

162

Info

The main fuse protects all power-consuming components of the vehicle. The main fuse is under the seat.

–

Switch off all power-consuming components and switch off the engine.

–

Remove the seat. (

p. 154)

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. 226)

Info

If the new fuse burns out, contact an authorized KTM-RC8 workshop.

–

Attach the protection covers



–

Fit the seat. (

p. 154)

Summary of Contents for 2008 1190 RC8 USA

Page 1: ...OWNER S MANUAL 2008 1190 RC8 USA ART NO 3211307en...

Page 2: ......

Page 3: ...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 th...

Page 4: ...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...

Page 5: ...nt function buttons on handlebar 33 Combination instrument activation and test 34 Display 35 Info display 36 Indicator lamps 37 Notes warnings on the combination instrument 38 ODO menu 41 FUELDISTANCE...

Page 6: ...horized KTM RC8 workshop 99 Important service tasks to be carried out by an authorized KTM RC8 workshop as additional job 102 MAINTENANCE WORK ON CHASSIS AND ENGINE 103 Jacking up motorcycle front 103...

Page 7: ...1 Checking tire air pressure 153 Removing the seat 154 Fitting the seat 154 Removing passenger seat 155 Fitting the passenger seat 155 Mounting helmet lock on vehicle 156 Removing the battery x 156 In...

Page 8: ...ervation for winter operation 217 STORAGE 218 Storage 218 Putting into operation after storage 219 TECHNICAL DATA ENGINE 220 Capacity engine oil 221 Capacity coolant 221 TECHNICAL DATA ENGINE TIGHTENI...

Page 9: ...require specialist 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...

Page 10: ...r replace 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...

Page 11: ...damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine...

Page 12: ...IMPORTANT NOTES 10 2 1 Overview of labels 700380 01...

Page 13: ...2 Type label for Canada 3 Type label for the USA 4 Emission control information 5 Noise emission information 6 Chain tension information 7 Information on suspension setting 8 Fuel evaporative system i...

Page 14: ...IMPORTANT NOTES 12 700381 01 Type label for Canada 700382 01 Type label for the USA...

Page 15: ...IMPORTANT NOTES 13 700383 01 Emission control information 700384 01 Noise emission information...

Page 16: ...IMPORTANT NOTES 14 700385 01 Chain tension information 700386 01 Information on suspension setting...

Page 17: ...arnings Be sure to pay attention to the notes and warnings given here Info Various notes and warning stickers are attached to the vehicle Do not remove any notes and warning stickers If they are missi...

Page 18: ...manual is an important component of the motorcycle and should be passed on to the new owner if the bike is sold Reporting safety defects If you believe that your vehicle has a defect which could cause...

Page 19: ...he following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporat...

Page 20: ...cal ordinances Consumer rights Warranty claims should be directed to a KTM workshop If you wish to make a complaint please contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 4400...

Page 21: ...19...

Page 22: ...VIEW OF VEHICLE 20 3 VIEW OF VEHICLE 3 1 View of vehicle front left side 700243 10...

Page 23: ...VIEW OF VEHICLE 21 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 24: ...VIEW OF VEHICLE 22 3 2 View of vehicle rear right side 700242 10...

Page 25: ...t 2 Supporting strap 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Hand brake lever 7 Chassis number type label 8 Rear brake caliper 9 Foot brake pedal 10 Eng...

Page 26: ...The type label for Canada is fixed to the frame on the left behind the steering head 4 2 Key number 700222 01 The key number Code number can be found on the KEYCODECARD Info You need the key number to...

Page 27: ...OF SERIAL NUMBERS 25 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 f...

Page 28: ...ber 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...

Page 29: ...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 handleb...

Page 30: ...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 swit...

Page 31: ...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 pr...

Page 32: ...n 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 s...

Page 33: ...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...

Page 34: ...CONTROLS 32 5 10 Combination instrument overview 400430 10 1 Display p 35 2 Function buttons 3 Indicator lamps p 37 4 Info display p 36...

Page 35: ...CONTROLS 33 5 11 Combination instrument function buttons on handlebar 600642 10 The MODE button is fitted on the handlebar front left The LAP button is fitted on the handlebar rear left...

Page 36: ...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...

Page 37: ...xcessive speed range of the engine The speed is displayed in kilometers per hour km h or in miles per hour Mph The time appears in segment Info After reconnecting the battery or changing the fuse the...

Page 38: ...ublic 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 di...

Page 39: ...hed The idling speed indicator lamp lights up green The gearbox 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 det...

Page 40: ...ment 400476 01 LOW FUEL appears on the info display if the minimum range falls below the specified value Distance 25 km 15 5 mi 400471 01 LOW BATTERY appears on the info display if the battery voltage...

Page 41: ...s 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 0...

Page 42: ...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...

Page 43: ...pTime shows the trip time on the basis of TripDist and resumes running as soon as a speed signal is received The calculation of this value starts with the first speed signal and ends three seconds aft...

Page 44: ...e 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 P...

Page 45: ...ter you reach the fuel reserve level MinRange shows the minimum range you can cover with the fuel reserve MaxRange shows the maximum range you can cover with the fuel reserve The possible range of the...

Page 46: ...STANCE TO Next Service appears in the info display DISTANCE TO Next Service shows the distance before the next service is necessary Press the button No function Press the button No function Press the...

Page 47: ...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 differe...

Page 48: ...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 la...

Page 49: ...he 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 display...

Page 50: ...ighest 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 i...

Page 51: ...the last reset For example this could be between two refueling stops RaceTrip is always running and counts up to 999 9 MaxRPM shows the highest engine speed reached during the RaceTrip TopSpeed shows...

Page 52: ...ay On the UNITS menu you can set the units for measuring speed distance and temperature On the OPTIONS menu you can switch the tire pressure check and external temperature display on off available as...

Page 53: ...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...

Page 54: ...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...

Page 55: ...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 th...

Page 56: ...s 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...

Page 57: ...tton 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 can set the lap blank time of the LAP button Press t...

Page 58: ...ly 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 can set the number of laps to cover in RACE mode Press the...

Page 59: ...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...

Page 60: ...asuring speed and distance On the SET C F menu you can set the unit for the temperature display On the BACK menu you switch back to the SET UP menu The symbol shows which menu you can activate with th...

Page 61: ...he 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...

Page 62: ...DE 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...

Page 63: ...off available as an accessory On the OPTION OUTTEMP menu you can switch the external temperature display on off On the BACK menu you switch back to the SET UP menu The symbol shows which menu you can...

Page 64: ...on briefly Press the MODE button briefly On the OPTION TPMS menu you can switch the tire pressure check on off available as an accessory Press the button Switches the tire pressure display on off Pres...

Page 65: ...he 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 externa...

Page 66: ...unction 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...

Page 67: ...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 Opens and exits CHANGE MODE Opens and exits CHANGE MODE SET...

Page 68: ...in front of the arrow is selected SET KM MILES menu Changes the unit Changes the unit No function Opens and exits SET KM MILES Opens and exits SET KM MILES SET C F menu Changes the unit Changes the un...

Page 69: ...tionary RACE mode The igni tion is on The motor cycle is stationary Menu can be activated ODO menu FUELDISTANCE menu FUELRANGE menu DISTANCE TO Next Service menu LAPSTOGO menu TOPSPEED menu LAP BESTLA...

Page 70: ...mode 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 UNITS menu SET KM MILES menu SET...

Page 71: ...isplayed Press the MODE button briefly Next display mode 5 41 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE mode 400447 01 Press the MODE button briefly and r...

Page 72: ...ges 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 43 Setting the clock with SET CLOCK Condition The i...

Page 73: ...on 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...

Page 74: ...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...

Page 75: ...LANK 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 Inf...

Page 76: ...riefly 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 s...

Page 77: ...ESET 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...

Page 78: ...ess 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...

Page 79: ...button briefly The selected unit appears on the left of the display Select the unit with the button or the button Press the MODE button briefly The settings are stored and the display changes to the...

Page 80: ...briefly You see ENABLED or DISABLED in the info display You can switch the external temperature display on off with the button or the but ton Press the MODE button briefly The settings are stored and...

Page 81: ...ONTROLS 79 5 51 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 82: ...r 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 53 Supporting strap 700244 01 The supporting strap is provide...

Page 83: ...in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen Warning Danger of accidents Impairment of handling characteristics and vehicle operation by a fitted helmet...

Page 84: ...footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 57 Shift lever 700...

Page 85: ...sitions can be seen in the picture The neutral or idle position is between the first and second gear 5 58 Foot brake pedal 700237 01 The foot brake pedal is in front of the right footrest The foot bra...

Page 86: ...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 positi...

Page 87: ...ront and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristics due to non ap...

Page 88: ...ever p 137 Adjust the footbrake pedal p 129 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 mot...

Page 89: ...cidents 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 mp...

Page 90: ...aggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted...

Page 91: ...egs p 108 Guideline Every 1 000 km 621 4 mi Check the chain tension p 131 Clean the chain p 130 Check the tire condition p 151 Check the tire air pressure p 153 Check the brake fluid level of the fron...

Page 92: ...consciousness 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 Note Engine failure High engine speeds in cold...

Page 93: ...pen 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 brea...

Page 94: ...key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle...

Page 95: ...s 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...

Page 96: ...For 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 reac...

Page 97: ...ced 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...

Page 98: ...o 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 Secur...

Page 99: ...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 wi...

Page 100: ...as 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...

Page 101: ...emory with KTM DIA 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 c...

Page 102: ...tioning 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 140 Check the rear brake linings p 14...

Page 103: ...air pressure p 153 Check the chain wear p 135 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 134 Check t...

Page 104: ...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...

Page 105: ...Move the handlebar to 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 firs...

Page 106: ...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 motor...

Page 107: ...e excessive 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 b...

Page 108: ...nding 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 s...

Page 109: ...nding 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 suspe...

Page 110: ...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 spri...

Page 111: ...ately 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 T...

Page 112: ...ockwise with a screwdriver up to the last perceptible click Info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock absorber type Guideline Compression dampin...

Page 113: ...ce on it yourself Info The high speed setting can be seen during the fast compression of the shock absorber 700256 01 Turn the adjusting screw clockwise with an open ended spanner until it stops Info...

Page 114: ...ast perceptible click Turn back counterclockwise the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payloa...

Page 115: ...compromise between easy handling and stabil ity 700341 10 Take the weight off the rear wheel and swingarm Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are...

Page 116: ...he 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 turn counterclockwise to red...

Page 117: ...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...

Page 118: ...s 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 adjust...

Page 119: ...e 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...

Page 120: ...ly 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...

Page 121: ...lush 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...

Page 122: ...gs 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...

Page 123: ...ed position 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 dire...

Page 124: ...t 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 lea...

Page 125: ...able 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...

Page 126: ...e 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 2...

Page 127: ...15 130 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 ce...

Page 128: ...he 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...

Page 129: ...sition 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...

Page 130: ...b 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 Ti...

Page 131: ...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 s...

Page 132: ...e 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 br...

Page 133: ...n 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 70...

Page 134: ...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 b...

Page 135: ...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 n...

Page 136: ...or 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...

Page 137: ...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...

Page 138: ...ing 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...

Page 139: ...es 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 t...

Page 140: ...e the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM RC8 workshop 700261 01 The brake fluid level must not fall below the MIN marking when the brak...

Page 141: ...mental 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 T...

Page 142: ...KTM brake linings If brake linings other than those supplied as originals are used there is no guarantee that they correspond to the original homologation The vehicle then no longer corresponds to the...

Page 143: ...f 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...

Page 144: ...stem 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 irr...

Page 145: ...brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 700265 01 Stand the vehicle upright Remove screw cover with...

Page 146: ...ickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x 9 43 Removing front wheel x Jack up the motorcycle rear end p 104 Jack up the mot...

Page 147: ...discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 9 44 Fitting front wheel x 200487 10 Warning Danger of accidents Reduced braking due to...

Page 148: ...the hand brake lever several times until the brake pads are lying correctly on the brake disc Take the front of the motorcycle off the work stand p 103 Take the rear of the motorcycle off the work sta...

Page 149: ...rear wheel backward until brake caliper support hangs free between the brake disc and the wheel rim Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the whe...

Page 150: ...se on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake Af...

Page 151: ...hings 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...

Page 152: ...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 t...

Page 153: ...absorbers 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...

Page 154: ...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...

Page 155: ...re 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 Fron...

Page 156: ...ar 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...

Page 157: ...move the seat p 154 Operate lever Take off the passenger seat toward the top 9 53 Fitting the passenger seat 700275 01 Position the passenger seat in the space provided Press down the passenger seat u...

Page 158: ...4 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 goggl...

Page 159: ...onnect the positive plus cable of the battery 700278 01 Remove screws Removing the securing bracket Pull the battery upwards out of the battery rack Info Never operate the motorcycle with a discharged...

Page 160: ...n the battery in the battery rack Info The poles of the battery must face the rear of the vehicle Position the bracket 700277 11 Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7...

Page 161: ...nd goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts o...

Page 162: ...vice life If the charge current the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery becomes discharg...

Page 163: ...ver 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 c...

Page 164: ...consuming components and switch off the engine Remove the seat p 154 700280 01 Remove protection covers Remove a defective main fuse with a needle nose plier Info A reserve fuse is located in the star...

Page 165: ...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 locat...

Page 166: ...er 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 inj...

Page 167: ...8 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 154 9 60 Changing the low beam bulb Note Damage to reflector Keep the gl...

Page 168: ...mbination 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 clam...

Page 169: ...n the headlight housing Low beam high beam H7 p 226 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 Po...

Page 170: ...g in the rubber holder 9 61 Changing the high 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 gla...

Page 171: ...MAINTENANCE WORK ON CHASSIS AND ENGINE 169 700297 01 Remove screws Remove cover 700298 01 Release the latch Remove the lamp cover...

Page 172: ...aining 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 226 Info Insert the headlight bulb so tha...

Page 173: ...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...

Page 174: ...eflector 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 o...

Page 175: ...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 226 Carefully posi...

Page 176: ...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...

Page 177: ...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 bet...

Page 178: ...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 ignit...

Page 179: ...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 th...

Page 180: ...he 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 ora...

Page 181: ...tion 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 400...

Page 182: ...9 67 Checking the coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling s...

Page 183: ...ning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is...

Page 184: ...led 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 180 Remove the cap of the c...

Page 185: ...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...

Page 186: ...lutch p 184 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...

Page 187: ...the gas Bowden cable with the adjusting screw Guideline Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten the counter nut 9 73 Handlebar height 700319 12 By removing or inserting the spacing sleeve...

Page 188: ...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 m...

Page 189: ...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 movin...

Page 190: ...peat 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...

Page 191: ...ristics Following modifications ride slowly at first to get the feel of the new handling characteristics Remove the seat p 154 700363 01 Remove screws with the bushings 700327 10 Setting a higher seat...

Page 192: ...t 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 vehic...

Page 193: ...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 e...

Page 194: ...rame M8 25 Nm 18 4 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 pl...

Page 195: ...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...

Page 196: ...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...

Page 197: ...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 the oil drain plug with the magnet O rings and o...

Page 198: ...96 700292 01 Thoroughly clean the magnet and oil screen of the oil drain plug 700288 01 Fit and tighten the oil drain plug with the magnet O rings and oil screen Guideline Oil drain plug M20x1 5 20 Nm...

Page 199: ...n screws Guideline Remaining chassis screws M5 5 Nm 3 7 lbf ft 9 80 Removing oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable pro...

Page 200: ...ing substances brake fluid batteries etc according to regulations Place a suitable container under the engine 700289 01 Remove screws Remove the oil filter cover with the O ring 700290 01 Pull the oil...

Page 201: ...ghten 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...

Page 202: ...ning 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...

Page 203: ...ays make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level p 193 9 83 Topping up engi...

Page 204: ...performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Replace the oil dipstick Danger Danger of poisoning Exhaust gases are poisonous and can resu...

Page 205: ...zer EFI control unit 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 instru...

Page 206: ...e the coolant hose x Thermostat defective Check the thermostat x Fuse 4 blown Change the fuses of individual power consumers p 163 Defect in radiator fan system Check the radiator fan system x Air in...

Page 207: ...when vehicle parked Recharge the battery x p 159 Battery is not charged by the generator Check charging voltage x Combination instrument shows nothing in display Fuse 1 blown Change the fuses of indi...

Page 208: ...1x short 1 second pause 4x short Possible cause Action Malfunction in transponder of black ignition key Use spare black ignition key Order new spare key Activate deactivate the ignition key p 176 Flas...

Page 209: ...encryption query from EFI control unit to immo bilizer control unit Activate the EFI control unit x Flash code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pa...

Page 210: ...ircuit A of throttle valve position generator x Input signal of throttle valve position generator circuit A too high Check circuit A of throttle valve position generator x Flash code EFI Warning lamp...

Page 211: ...k pressure sensor induction manifold cylinder 2 x Input signal from pressure sen sor induction manifold cylin der 2 too high Check pressure sensor induction manifold cylinder 2 x Flash code EFI Warnin...

Page 212: ...mp MIL flashes 1x long 7x short Possible cause Action Malfunction in lambda probe circuit cylinder 1 Check lambda probe cylinder 1 x Flash code EFI Warning lamp MIL 18 EFI Warning lamp MIL flashes 1x...

Page 213: ...cuit cylinder 2 Check injection valve cylinder 2 x Flash code EFI Warning lamp MIL 37 EFI Warning lamp MIL flashes 3x long 7x short Possible cause Action Malfunction in ignition coil cir cuit cylinder...

Page 214: ...probe cylinder 1 x Flash code EFI Warning lamp MIL 46 EFI Warning lamp MIL flashes 4x long 6x short Possible cause Action Malfunction or short circuit to ground in lambda probe heating circuit cylinde...

Page 215: ...valve x Flash code EFI Warning lamp MIL 54 EFI Warning lamp MIL flashes 5x long 4x short Possible cause Action Interruption short circuit to ground in secondary air valve circuit Check the secondary...

Page 216: ...g 9x short Possible cause Action Connection of pressure sensor induction manifold cylinder 2 leaky Check pressure sensor induction manifold cylinder 2 x Flash code EFI Warning lamp MIL 72 EFI Warning...

Page 217: ...according 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 e...

Page 218: ...te 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 130 Treat bare metal except for brake discs and...

Page 219: ...alt If the vehicle has been used on salted roads clean it with cold water Warm water intensifies the effects of salt Clean the motorcycle p 215 Treat the engine swingarm and all other bare or galvaniz...

Page 220: ...pty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 215 Change the engine oil and filter clean the oil screen x p 194 Check t...

Page 221: ...p 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 sta...

Page 222: ...st at 20 C 68 F 0 25 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...

Page 223: ...tor 12 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 C...

Page 224: ...Nm 7 4 lbf ft Loctite 243 Screw freewheel ring M6 13 Nm 9 6 lbf ft Loctite 648 Screw generator cover M6 10 Nm 7 4 lbf ft Stud chain shaft M6 8 Nm 5 9 lbf ft Screw coolant connection on cylinder head...

Page 225: ...15 Nm 11 1 lbf ft Loctite 243 Plug crankshaft retainer M8 15 Nm 11 1 lbf ft Screw engine housing M8 18 Nm 13 3 lbf ft Screw engine console M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing supp...

Page 226: ...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 l...

Page 227: ...ont Double disc 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 Fro...

Page 228: ...33 in Weight without fuel approx 184 kg 406 lb Maximum permissible front axle load 200 kg 441 lb Maximum permissible rear axle load 220 kg 485 lb Maximum permissible total weight 380 kg 838 lb Batter...

Page 229: ...120 70 ZR 17 M C 58W TL Pirelli Dragon Supercorsa Pro 190 55 ZR 17 M C 75W TL Pirelli Dragon Supercorsa Pro For further information see the Service section under http www ktm com 18 2 Capacity fuel T...

Page 230: ...Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns full payload 3 turns Spring le...

Page 231: ...urns Sport 1 turn full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Spo...

Page 232: ...TECHNICAL DATA SHOCK ABSORBER 230 Spring length 160 mm 6 3 in 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...

Page 233: ...ng chassis nuts M6 15 Nm 11 1 lbf ft Screw exhaust heat shield M6 15 Nm 11 1 lbf ft Screw exhaust clamp M6 8 Nm 5 9 lbf ft Screw foot brake pedal M6 15 Nm 11 1 lbf ft Loctite 243 Screw footbrake pedal...

Page 234: ...g stem M8 20 Nm 14 8 lbf ft Screw handlebar stub M8 20 Nm 14 8 lbf ft Screw steering damper fixing bracket M8 20 Nm 14 8 lbf ft Loctite 243 Screw steering damper clamp on con sole M8 20 Nm 14 8 lbf ft...

Page 235: ...tite 243 Remaining chassis screws M10 45 Nm 33 2 lbf ft 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 Threa...

Page 236: ...trol and Motorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using infer...

Page 237: ...responding properties KTM recommends Motorex products fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 239 SAE p 239 SAE 5W 40 Guideline Use o...

Page 238: ...ecommends Motorex products Supplier Motorex Racing Fork Oil Hydraulic fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications o...

Page 239: ...11 Cleaning 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 recomme...

Page 240: ...commends 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...

Page 241: ...intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle and ATV engines With most motorcycles and ATVs the gearbox and the clutch are...

Page 242: ...ear brake checking 143 Brakes 95 Braking 95 C Chain checking for dirt 129 checking for wear 135 cleaning 130 Chain sliding guard checking 136 Chain tension adjusting 132 checking 131 Chassis number 24...

Page 243: ...l 208 214 immobilizer 206 207 Flasher switch 29 Foot brake pedal 83 adjusting 129 Footbrake pedal stub adjusting 128 Footrest position 122 adjusting 122 Fork 105 compression damping adjusting 105 fork...

Page 244: ...times displaying 68 Light switch 28 Loading the vehicle 87 Low beam bulb changing 165 Luggage 87 M Main fuse changing 161 Maintenance 8 Materials 8 Maximum speed displaying 69 Motorcycle cleaning 215...

Page 245: ...orber checking 151 Rear sprocket engine sprocket checking for wear 134 Rear wheel fitting 148 removing 146 Riding 92 starting up 91 ROAD mode setting 70 S Seat fitting 154 removing 154 Seat lock 81 Se...

Page 246: ...orage 218 Supporting strap 80 T Technical data chassis 225 227 chassis tightening torques 231 233 engine 220 221 engine tightening torques 222 224 fork 228 shock absorber 229 230 Tire air pressure che...

Page 247: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2008 Photo Mitterbauer 3211307en 3211307en...

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KTM 2008 1190 RC8 USA, Owner'S Manual

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