KTM 2010 1190 RC8 Owner'S Manual Download

Page: 196 / 258

MAINTENANCE WORK ON FRAME AND ENGINE

194

9.71

Checking the play in the throttle cable

400192-10

–

Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the throttle cable.

Throttle cable play

3… 5 mm (0.12… 0.2 in)

» If the throttle cable play does not meet specifications:

–

Adjust the play in the throttle cable.

(

p. 195)

Danger

Danger of poisoning

Exhaust gases are poisonous and inhaling them may result

in unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.

–

Start the engine and let it run idle. Move the handlebar to and fro over the entire steer-
ing range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the play in the throttle cable.

(

p. 195)

Summary of Contents for 2010 1190 RC8

Page 1: ...OWNER S MANUAL 2010 1190 RC8 USA Art no 3211524en ...

Page 2: ......

Page 3: ...at the time of going to print However it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG 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 ad...

Page 4: ...ds is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ... instrument overview 34 Combination instrument function buttons on handlebar 35 Combination instrument activation and test 36 Display 37 Info display 38 Indicator lamps 39 Notes warnings on the combination instrument 40 Overview of ROAD mode 44 Odometer menu ODO Trip 1 45 Odometer menu ODO Trip 2 46 FUELDISTANCE menu 47 FUELRANGE menu 48 DISTANCE TO Next Service menu 49 Overview of RACE mode 50 LA...

Page 6: ...98 Starting up 99 Shifting riding 100 Braking 103 Stopping parking 104 Refueling 105 SERVICE SCHEDULE 107 Service schedule 107 MAINTENANCE WORK ON FRAME AND ENGINE 110 Jacking up motorcycle front 110 Taking front of motorcycle off work stand 110 Jacking up motorcycle at the rear 111 Taking the rear from the workstand 111 Fork shock absorber 112 Adjusting the compression damping of the fork 112 Adj...

Page 7: ...ecking the tire pressure 162 Removing the seat 163 Fitting the seat 163 Removing the passenger seat 164 Mounting the passenger seat 164 Mounting the helmet lock on the vehicle 165 Removing the battery x 165 Installing the battery x 167 Recharging the battery x 169 Changing the main fuse 171 Changing the fuses of individual power consumers 173 Changing the low beam bulb 175 Changing the high beam b...

Page 8: ...ER OPERATION 226 Conservation for winter operation 226 STORAGE 227 Storage 227 Putting into operation after storage 228 TECHNICAL DATA ENGINE 229 Capacity engine oil 230 Capacity coolant 230 TECHNICAL DATA ENGINE TIGHTENING TORQUES 231 TECHNICAL DATA CHASSIS 234 Lighting equipment 235 Tires 236 Capacity fuel 236 TECHNICAL DATA FORK 237 TECHNICAL DATA SHOCK ABSORBER 238 TECHNICAL DATA CHASSIS TIGHT...

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: ...vice or replace worn parts before the limit specified in the service schedule is reached Pay careful attention to the prescribed running in period and inspection and maintenance intervals Close adherence to these periods will significantly lengthen the service life of your motorcycle Warranty The work described in the service schedule must be carried out exclusively in an authorized KTM RC8 worksh...

Page 11: ...is used for screw connections be sure to comply with the manufacturer s specific instructions on its usage Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Following repairs or servicing the vehicle must be checked for roadworthiness Transport Note Danger of damage The parked vehicle may roll away or fall ov...

Page 12: ... can also lead to problems with the environment and conflict with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To ensure the future of motorcycle sport make sure you use the motorcycle legally demonstrate a consciousness for the environ ment and respect the rights of others ...

Page 13: ...IMPORTANT INFORMATION 11 ...

Page 14: ...IMPORTANT INFORMATION 12 2 1 Overview of labels 700380 11 ...

Page 15: ...bel for the USA 4 Emission control information 5 Noise emission information 6 Chain tension information 7 Information on suspension setting 8 Fuel evaporative system information 9 Pillion seat locking information is on the underside of the pillion seat 600961 01 Information on putting into operation ...

Page 16: ...IMPORTANT INFORMATION 14 600932 01 Type label for Canada 600930 01 Type label for the USA ...

Page 17: ...IMPORTANT INFORMATION 15 600959 01 Emission control information 600933 01 Noise emission information ...

Page 18: ...IMPORTANT INFORMATION 16 600928 01 Chain tension information 100486 10 Information on suspension setting ...

Page 19: ...ion is on the underside of the pillion seat Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are missing you or others may not recognize potential hazards and may therefore be injured ...

Page 20: ...ins useful information and tips to help you operate and handle your motorcycle Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual is an important component of the motorcycle and should be handed over to the new owner if th...

Page 21: ... 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the 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 incorporated into any new vehicle for the purpose of noise control...

Page 22: ...tate and local ordinances Consumer rights Warranty claims should be submitted to an authorized KTM workshop If you are not satisfied please contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Your rights may vary u...

Page 23: ...21 ...

Page 24: ...VIEW OF VEHICLE 22 3 1 View of vehicle front left side 700243 10 ...

Page 25: ...VIEW OF VEHICLE 23 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 26: ...VIEW OF VEHICLE 24 3 2 View of vehicle rear right side 700242 10 ...

Page 27: ...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 lever 10 Engine number 11 Brake calipers front ...

Page 28: ...umber The type label for Canada is located on 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 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...

Page 29: ...N OF SERIAL NUMBERS 27 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 30: ...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 31: ... 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 32: ...switched on High beam on The light switch is in the upper position In this position the low beam the high beam and the tail light are switched on 5 4 Headlight flasher switch 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 a...

Page 33: ...o the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch housing 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 ...

Page 34: ...e black ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and 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 switc...

Page 35: ...he ignition key is withdrawn The red warning lamp flashes at 15 second intervals after one minute The red warning lamp can also indicate errors by flashing Info The ignition key contains electronic components Never attach multiple ignition keys to a single key ring this may cause mutual interference and lead to problems A lost black ignition key must be deactivated to prevent unauthorized persons ...

Page 36: ...CONTROLS 34 5 11 Combination instrument overview 400580 10 1 Display p 37 2 Function buttons 3 Indicator lamps p 39 4 Info display p 38 ...

Page 37: ...E 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 38: ...ents 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 39: ...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 40: ...public roads Menu 2 is RACE mode for riding on race tracks It allows riders to time laps themselves If the general warning lamp lights up the corresponding message is shown periodically in the info display Information repeat 45 s The information shown in the info display can be controlled with the function buttons ...

Page 41: ...ached The idle speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on EFI warning lamp MIL lights up flashes red The OBD has detected an emission or safety critical fault The general warning lights up yellow An operating safety warning mes sage was detected This is also shown periodically in the info display...

Page 42: ...ument 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 43: ...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 front cylinder coolant temperature sensor is faulty ...

Page 44: ...olant temperature sensor values differs by more than the specified value Coolant temperature 10 C 50 F 400467 01 ICE appears on the info display if the external temperature falls below the specified value Temperature 3 C 37 F ICE disappears if the external temperature rises above the specified value Temperature 4 C 39 F ...

Page 45: ...CONTROLS 43 ...

Page 46: ...CONTROLS 44 5 18 Overview of ROAD mode 400942 10 ...

Page 47: ...Trip 1 shows the distance covered since the last reset For example between two refueling stops Trip 1 is always running and counts up to 9999 9 Time 1 shows the journey time on the basis of Trip 1 and 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 wi...

Page 48: ...last reset For example between two refueling stops Trip 2 is always running and counts up to 9999 9 Time 2 shows the journey time on the basis of Trip 2 and resumes running as soon as a speed signal is 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 fun...

Page 49: ...red since the fuel reserve level was reached Info This is displayed only after you reach the fuel reserve level OuterTemp shows the external temperature The external temperature can be switched on and 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 ...

Page 50: ...fter 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 the M...

Page 51: ...ISTANCE 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 52: ...CONTROLS 50 5 24 Overview of RACE mode 400943 10 ...

Page 53: ...e stopwatch is running in the background If a P appears after LAPSTOGO the stopwatch in the background is active but waiting for a speed signal The time is not running This function is controlled by the button LAP LastLap shows the lap time of the last lap 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 l...

Page 54: ...pears after TOPSPEED the stopwatch is not running in the background This function is controlled by the button LAP TOPSPEED shows the highest lap speed LastLap shows the maximum speed of the last lap 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 wi...

Page 55: ...AP LastLap appears in the info display LAP shows the selected lap BESTLAP shows the number of the lap with the best lap time LastLap shows the time of the lap behind LAP Lap shows the difference to the 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 dis...

Page 56: ...ows the lap in which the highest maximum speed was reached TopSpeed shows maximum speed of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press 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...

Page 57: ...d 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 MODE...

Page 58: ...CONTROLS 56 5 30 Overview of SET UP mode 400945 01 ...

Page 59: ...CONTROLS 57 Settings in SET UP mode CHANGE MODE menu SET CLOCK menu SETTINGS menu UNITS menu OPTIONS menu EXIT SETUP menu ...

Page 60: ...lay 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 an accessory 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 Pre...

Page 61: ...ds 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 62: ...LOCK 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 value ...

Page 63: ...tton On the SET NUM LAPS menu you set the number of laps to cover in RACE mode On the TRIP F RESET menu you can set the reaction time of the fuel reserve display to changes of the fuel level On the 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 but...

Page 64: ...ay 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 S...

Page 65: ... the MODE button briefly Press the button once until the symbol shows LAP BLANK T in the info display Press the MODE button briefly On the LAP BLANK T menu you set the lap blank time of the LAP button 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...

Page 66: ...button briefly Press the button twice until the symbol shows 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 P...

Page 67: ...he button three times until the symbol shows TRIP F RESET in the info dis play Press the MODE button briefly On the TRIP F RESET menu you can set the reaction time of the fuel reserve display to 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 ...

Page 68: ...suring 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 menu ...

Page 69: ...n 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 exit S...

Page 70: ... MODE button briefly Press the button once until the symbol shows SET C F in the info display Press the MODE button briefly On the SET C F menu you can set the unit for the temperature display Press 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 MODE bu...

Page 71: ...ff available as an accessory On the OPTION OUTTEMP menu you can switch the external temperature display on off On the BACK menu you can switch back to the SET UP menu The symbol shows which menu you 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 se...

Page 72: ...utton 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 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 MODE b...

Page 73: ... the symbol shows OPTION OUTTEMP in the info display Press the MODE button briefly On the OPTION OUTTEMP menu you can switch the external temperature display on off Press the button Switches the 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 onds Ope...

Page 74: ...es 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 except...

Page 75: ...e 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 The a...

Page 76: ...enu 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 arrow is...

Page 77: ...ACE 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 LAP...

Page 78: ...he 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 45 Displaying lap times Condition The ignition is on The motorcycle is stationary RACE Mode ...

Page 79: ...displayed Press the MODE button briefly Next display mode 5 46 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE Mode 400447 01 Press the MODE button briefly and 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 displaye...

Page 80: ...nges to the SET UP menu Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 5 48 Setting the clock with SET CLOCK Condition The 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 shows SET CLOCK in the info display Press the MODE button b...

Page 81: ...00460 01 Press the button and the button for 3 5 seconds Press the button twice until the symbol appears in front of SETTINGS in the info display Press the MODE button briefly Press the MODE button briefly RPM1 and RPM2 appear in 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 which the shift warning light star...

Page 82: ...e settings are stored and the display changes to the SETTING menu Info At delivery RPM1 is set to 10000 and RPM2 to 10500 Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 5 50 Setting the blank time of the L...

Page 83: ...th 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 ...

Page 84: ...button 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 symb...

Page 85: ... button briefly TRIPF RESET appears in the info display with the reaction time Info At delivery TRIPF RESET is set to 300 seconds Set the reaction time of the fuel reserve display with the button or 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 bu...

Page 86: ... info display Press the MODE button briefly Press the MODE button briefly The selected unit appears on the left of the display Select the unit with the button or the button Press the MODE button briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the but...

Page 87: ...E 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 shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SE...

Page 88: ... 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 shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly u...

Page 89: ... of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap ...

Page 90: ...at it is closed correctly Change cloth ing that came into contact with fuel Immediately clean skin that came into contact with fuel using soap and water Close the filler cap Push down the filler cap slightly until the lock closes Remove the ignition key and close the cover 5 58 Supporting strap 700244 01 The supporting strap is provided for the passenger to hold on to ...

Page 91: ... 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 ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the jour ney Always remove the helmet lock before starting out ...

Page 92: ...r 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 62 Shift lever 700239 01 The shift lever is mounted on the left of the engine ...

Page 93: ...ositions can be seen in the picture The neutral or idle position is between the first and second gear 5 63 Foot brake lever 700237 01 The foot brake lever is in front of the right footrest The foot brake lever operates the rear brake ...

Page 94: ... 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 95: ...tterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic 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 Reduc...

Page 96: ...ke lever p 145 Adjust the foot brake lever p 135 Adjust the shift lever p 130 Get used to handling the vehicle on suitable terrain before making a longer trip Try also to ride as slowly as possible to get a better feeling for the motorcycle Hold the handlebars firmly with both hands and keep your feet on the footrests when riding Run the engine in p 94 6 2 Running the engine in Do not exceed the s...

Page 97: ...andling 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 accidents Poor ...

Page 98: ...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 99: ...he fuel level Check the chain tension p 138 Clean the chain p 136 Check the tire condition p 160 Check the tire pressure p 162 Check the front brake fluid level p 145 Check the rear brake fluid level p 149 Check the front brake linings p 148 Check the rear brake linings p 151 Check the brake system Check the coolant level p 189 Check the adjustment and smooth operation of all controls Check that t...

Page 100: ... in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life ...

Page 101: ...ting the engine DO NOT apply the throttle If you apply the throttle during the starting procedure the engine management shuts off the injectors and the engine will not start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clutc...

Page 102: ...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 103: ...ires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and 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 fix...

Page 104: ...e clutch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines After reaching maximum speed by fully opening the throttle turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lo...

Page 105: ... Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Danger of accidents Reduced braking effect caused by 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 Failure of brake system If the foo...

Page 106: ...g down two gears but do not race the engine You will require less braking force and the brakes will not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never 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 S...

Page 107: ...er continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency OFF switch is provided for emergency situations 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 vehicle onto it Lock the steering by turning it to the left press black ig...

Page 108: ... 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 catalytic converter Leaded fuel will destroy the catalytic converter You should there fore use unleaded fuel only 700321 01 Switch off the engine Open the filler cap ...

Page 109: ...ck that brake lines are undamaged and free of leaks Check the rear brake fluid level p 149 Check the free travel of the foot brake lever p 135 Check that the shock absorber and fork are leak tight If necessary and depending on use service the fork and shock absorber Check the swingarm bearings x Check wheel bearings for play x Check the tire condition p 160 Check the tire pressure p 162 Check the ...

Page 110: ...ifreeze and coolant level Check the wiring harness of the throttle valve body for damage and correct routing x Check cables for damage and kink free routing x Check that the cables are undamaged routed without sharp bends and set correctly Check the play in the throttle cable p 194 Change the air filter Clean the air filter box x Check the fluid level of the hydraulic clutch p 192 Check the screws...

Page 111: ...hiness and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride x Make the service entry in KTM DEALER NET and in the service record x K10N Once after 1 000 km 621 4 mi K100A Every 10 000 km 6 214 mi or annually K200A Every 20 000 km 12 428 mi or every 2 years or after every sporting use K400A Every 40 000 km 24 855 mi or every 4 years ...

Page 112: ... to the straight ahead position Align the work stand at the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the motorcycle at the front 9 2 Taking front of motorcycle off work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the moto...

Page 113: ... work stand Work stand adapter 61029055120 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the link fork and the adapters and jack up the motorcycle 9 4 Taking the rear from the workstand Note Danger of damage The parked vehicle may 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 114: ...g screw up against the stop with force set the last discernible click as the last position These adjustments should be understood as a guideline and should always be the basis of your own personal 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 Adjusting the compression dampin...

Page 115: ...ng 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 energ...

Page 116: ...ound 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 The best spring preload setting is achieved when it is set for the weight of the rider an...

Page 117: ...onding to 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 dampin...

Page 118: ...d ranges Dual Compression Control The terms low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed of the motorcycle Changes in the low speed range settings have an impact on the high speed range and vice versa 9 11 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts ...

Page 119: ...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 damping 9 12 Adjusting the high speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is fill...

Page 120: ...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 damping 9 13 Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high densit...

Page 121: ...ise to reduce damping 9 14 Adjusting the spring preload of the shock absorber x Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spring preload defines the initial situation of the spring process on the shock absorber The best spring pre...

Page 122: ... 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 123: ...t the manner of riding style and the road conditions For high speeds an adjustment with high damping can be chosen in order to use the steer ing damping function optimally In slow tight bends intensive 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 124: ...ons 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 a...

Page 125: ...ont 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 by tu...

Page 126: ...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 vehicle sags toward the front 700353 01 Align the fork leg in the desired position by means of the fork rings Guideline Upper triple clamp flush with upp...

Page 127: ...he vehi cle to become more stable but also more difficult to handle 700352 01 Tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Tighten screw Guideline Screw handlebar stub M8 20 Nm 14 8 lbf ft Repeat the adjustment on the other fork leg Info The vehicle level setting on both fork legs must be identical ...

Page 128: ...ide behavior Following modifications ride slowly at first to get the feel of the new ride behavior 700331 01 Loosen screw but do not remove it 700332 01 Turn eccentric shaft to the desired 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 directions ...

Page 129: ...otrest system enables an individual setting of the footrest height and an individual adjustment of the controls The lower footrest position enables a more comfortable knee angle the upper footrest posi 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 ...

Page 130: ...bracket with spacers and screws Guideline Standard Lower position Info The adjustable 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 ...

Page 131: ...MAINTENANCE WORK ON FRAME AND ENGINE 129 700309 01 Repeat adjustment work on the footrest bracket on the other side Adjust the shift lever p 130 Adjust the foot brake lever p 135 ...

Page 132: ...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 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 133: ...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 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 134: ...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 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 Loctite...

Page 135: ...position 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 check its operation There must be a minimum distance between the moving parts of the shift lever and other parts of the vehicle Guideline Min...

Page 136: ...700305 01 Remove the screw with the foot brake lever stub Position the foot brake lever stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tighten the screw Guideline Bolt foot brake lever stub M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 137: ...eleased and the hex nut is locked 700346 01 Check the foot brake lever setting Info Position of the foot brake lever may vary considerably depending on the set ting 9 26 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating ...

Page 138: ...e lever 3 5 mm 0 12 0 2 in Info The piston rod should not move in the process If the free travel does not meet specifications Adjust the free travel 9 27 Checking for chain dirt 400678 01 Check the chain for loose dirt If the chain is very dirty Clean the chain p 136 9 28 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suita...

Page 139: ...nmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 247 After dry...

Page 140: ...ak On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 700322 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 ...

Page 141: ...gine 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 the chain tension and correct if necessary...

Page 142: ... 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 adj...

Page 143: ...sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 144: ...m 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed A new chain wears out faster on old worn sprockets For safety reasons the chain has no chain joint 700351 11 Check the chain sliding guard for wear at the opening If the rivets of the chain are no longer visible at the low...

Page 145: ...ill be pleased to help 100135 10 Check the thickness of the brake disc in several places to see if it is within the speci fied wear tolerance Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4 0 mm 0 157 in If the brake disc thickness is less than the specified value Change the brake discs x Check the brake discs for damage cracking and def...

Page 146: ...lp 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 disc 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 damage cracking and deformation If damage cracks or deformation ...

Page 147: ...uid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM RC8 workshop will be pleased to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the...

Page 148: ... in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM RC8 workshop will be pleased to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with...

Page 149: ...is corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container 700262 01 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Loosen screw Remove cap with membrane Add brake fluid to the MAX level Brake fluid DOT 4 DOT 5 1 p 243 Position the cap with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid...

Page 150: ...ced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM RC8 workshop will be pleased to help Note Danger of accidents Reduced braking efficiency caused by 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 greatly reduced and the brake discs are rendered...

Page 151: ... brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM RC8 workshop will be pleased to help 700264 01 Stand the vehicle upright Check the brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN mark Add rear brake fluid x p 149 9 40 Adding rear brake fluid x Warning Danger of accidents Failure of the brake sy...

Page 152: ...rake fluid of the front and rear brakes according to the service schedule Your authorized KTM RC8 workshop will be pleased to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil sea...

Page 153: ...rake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM RC8 workshop will be pleased to help Note Danger of accidents Reduced braking efficiency caused by 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 gre...

Page 154: ...r is encountered Change the rear brake linings x 9 42 Removing the front wheel x Jack up the motorcycle at the rear p 111 Jack up the motorcycle at the front p 110 700271 10 Remove the screws from both brake calipers Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc Pull the brake calipers carefully back from the brake discs and hang them to one side...

Page 155: ...o push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 301443 12 Remove spacers ...

Page 156: ...place the wheel bearing x Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 247 301444 10 Insert the wide spacer on the left hand side when looking in the direction of travel Info The arrow indicates the direction of rotation of the front wheel Insert the narrow spacer on the right hand side when viewed in the direction of travel ...

Page 157: ...700271 12 Position the brake calipers and check that the brake linings are seated correctly Mount screws on both brake calipers but do not tighten yet Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point Fix the hand brake lever in the activated posi tion The brake calipers align themselves Tighten screws on both brake calip...

Page 158: ...and compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Fork end pinch bolts M8 15 Nm 11 1 lbf ft 9 44 Removing the rear wheel x Jack up the motorcycle at the rear p 111 700311 01 Remove nut Remove chain adjuster Remove the axle ...

Page 159: ...arefully without damaging the rim or brake disc Info Do not operate the foot brake when the rear wheel is removed 9 45 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency 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 of accidents No braking effect when operati...

Page 160: ... is damaged or worn Replace the wheel bearing x Install the spacer Clean the thread of the axle and nut Clean the mating surfaces of the brake caliper frame and swingarm 700314 01 Push the brake caliper frame completely to the rear Position the rear wheel and place the brake caliper frame between the rim and the brake disc Slide the brake caliper onto the brake disc Position the rear wheel on the ...

Page 161: ...lace 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 press up against the brake disc and there is a pressur...

Page 162: ...e is damaged or worn Change the shock absorber x Position the rear sprocket carrier Info A set of bolts and shock absorbers should have as little free play as possible to increase the service life of the shock absorbers Install the rear wheel x p 157 9 47 Checking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have da...

Page 163: ...riding at alternating angles The full grip levels are not achieved until the tires have been run in Info The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires exhi...

Page 164: ...e latest after five years If a tire is more than five years old Change the tires 9 48 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure tool kit comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 5 bar 36 psi Rear 2 5 bar 36 psi Ti...

Page 165: ... key in the seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards 9 50 Fitting the seat 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 cor...

Page 166: ...ng 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 167: ...0 Guide the steel cable through the helmet opening Then position the free loop of the steel cable on the lug Position the helmet carefully on the side of the vehicle Fit the seat p 163 9 54 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact w...

Page 168: ...onic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Switch off all power consumers and the engine Remove the seat p 163 700276 10 Disconnect negative minus cable of the battery 700277 10 Remove the cover of the positive terminal Disconnect the positive plus cable of the battery ...

Page 169: ...ve screws Removing the securing bracket Pull the battery up and out of the battery rack 9 55 Installing the battery x 700279 01 Position the battery in the battery rack Info The terminals of the battery must face the rear of the vehicle Position the bracket ...

Page 170: ...ten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Reconnect the positive plus cable of the battery Position cover of the positive terminal 700276 11 Reconnect the negative minus cable of the battery Fit the seat p 163 Set the clock with SET CLOCK p 78 ...

Page 171: ...inse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or to a recycling center that ac...

Page 172: ...escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free i e the acid level does not have to be checked Switch off all ...

Page 173: ...lid Charge the battery at no more than 10 of the capacity specified on the battery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Fit the seat p 163 Set the clock with SET CLOCK p 78 9 57 Changing the main fuse Warning Fire h...

Page 174: ...ers and the engine Remove the seat p 163 700280 01 Remove protection covers Remove the faulty main fuse Info A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 235 Tip Place the spare fuse in the starter relay so that it is available if needed Attach the protection covers Fit the seat p 163 Set the clock with SET CLOCK p 78 ...

Page 175: ...ical 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 the engine Remove the seat p 163 700281 01 Open fuse box cover ...

Page 176: ...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 15A spare fuses Use spare fuses with the correct rating only Fuse 75011088010 p 2...

Page 177: ...to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine 700293 01 Fold up the combination instrument Pull the lug out of the rubber retainer Remove the rubber retainer ...

Page 178: ...sh off the retaining clamp on both sides squeeze and fold to the side Remove headlight bulb 700296 01 Position the new headlight bulb in the headlight housing Low beam high beam H7 base PX26d p 235 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 179: ...77 400422 10 Position the lug of the lamp cover in the notch Engage the latch Check that the lighting is functioning properly 700293 11 Position the rubber holder Fold down the combination instrument Position the lug in the rubber retainer ...

Page 180: ...b Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine 700297 01 Remove screws Remove the cover ...

Page 181: ...or Push off the retaining clamp on both sides squeeze and fold to the side Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam high beam H7 base PX26d p 235 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 182: ... lamp cover in the notch Engage the latch Check that the lighting is functioning properly 700335 10 Position the 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 183: ...ulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine 700297 01 Remove screws Remove the cover ...

Page 184: ...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 W5W base W2 1x9 5d p 235 Carefully position the holder with the bulb in the holder in the headlight ...

Page 185: ... lamp cover in the notch Engage the latch Check that the lighting is functioning properly 700335 11 Position the 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 186: ...e vertically at a distance in front of the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary ...

Page 187: ... and deactivating 700234 10 Loss of a black ignition key second black ignition key available If a black ignition key is lost or replaced the black ignition keys must be individually activated deactivated using the orange programming key This will also prevent the vehi cle from being operated without authorization with the lost black ignition key The following procedure deactivates all activated bl...

Page 188: ...he ON position EFI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator 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 OFF position Pull out the orange programming key The lost ...

Page 189: ... keys are deactivated Order a new black ignition key according to the key number on the KEYCODECARD and activate it Activating ignition key You can activate or deactivate up to four black ignition keys Only the black ignition keys programmed during an activation procedure are valid All black ignition keys not programmed during the activation procedure are invalid but can be reprogrammed in a furth...

Page 190: ...t the last 4 steps with the respective ignition key Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position EFI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and flashes according to the number of functioning black ignition keys including t...

Page 191: ...ow into the compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system 400416 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 9 66 Checking the coolant level Warning Danger of scalding During motor...

Page 192: ... Add coolant bleed the cooling system x If the coolant level in the compensating tank does not meet specifications but the tank is not empty Check the cooling system for leaks x Fill the cooling system compensating tank p 190 9 67 Filling the cooling system compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the rad...

Page 193: ...e damage Impaired cooling efficiency due to air trapped in the cooling system After draining coolant and refilling the cooling system the motorcycle must be raised at the front according to the model type This is the only way of ensuring that the cooling system is filled without air bubbles Your authorized KTM RC8 workshop will be pleased to help 700324 01 Check the coolant level p 189 Remove the ...

Page 194: ... 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 69 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake f...

Page 195: ...h p 193 9 70 Correcting fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 700284 01 Remove screw cap with membrane Correct the fuel level Guideline The fluid level must be between the MIN and MAX markings Hydraulic fluid 15 p 245 Refit the...

Page 196: ...ust the play in the throttle cable x p 195 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fr...

Page 197: ...t Set the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut Mount the protective cover 9 73 Handlebar height 700319 12 By removing or inserting spacing sleeves you can set the handlebar height at two differ ent positions Length of distance sleeve 15 mm 0 59 in With distance sleeves the handlebar stub is positioned low for spo...

Page 198: ...rew 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 screw Guideline Rema...

Page 199: ...ering 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 between the up...

Page 200: ...ents 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 32 48 in ...

Page 201: ...ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Remove the seat p 163 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 202: ...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 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 203: ...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 Sc...

Page 204: ...ame 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 sensor fix the plug in cable binder in the remaining free drill hole Info Check the cable routing The cable of the lambda sensor should not be taut ...

Page 205: ...ked 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 not at the specified level Ad...

Page 206: ...Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Dra...

Page 207: ...ke 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 207 Completely drain the engine oil ...

Page 208: ...100773 10 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 209 ...

Page 209: ...hten screws Guideline Screw trim painted M5 3 5 Nm 2 58 lbf ft 9 80 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water ...

Page 210: ...ke fluid etc should be disposed of as stipulated in applicable 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 211: ...2 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 244 External temperature 0 C 32 F Engine oil SAE 5W 40 p 244 Remove the dipstick and top up the engine oil Engine oil 1st quantity 3 00 l 3 17 qt E...

Page 212: ... 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 32 F Engine oil SAE 10W 50 p 244 External temperature 0 C 32 F Engine oil SAE 5W 40 p 244 Replace the oil dipstick Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may...

Page 213: ...esults in premature wear to the engine Check the engine oil level p 203 700301 01 Remove the dipstick and add engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 244 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 244 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Replace oil dipstic...

Page 214: ...ng them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 203 ...

Page 215: ...zer active Read the immobilizer blink code EFI control unit not activated Encode the EFI control unit x Malfunction in CAN bus communica tion Read out the trouble code memory using the KTM diagnostics tool 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 Read out...

Page 216: ...ode memory using the KTM diagnostics tool x Engine overheats HIGH TEMP Too little coolant in cooling system Check the cooling system for leaks x Check the coolant level p 189 Cooling fins very dirty Clean cooling fins Kinked or damaged radiator hose Change the coolant hose x Thermostat defective Check the thermostat x Fuse 4 blown Change the fuses of individual power consumers p 173 Defect in radi...

Page 217: ...e light and horn do not work Fuse 3 blown Change the fuses of individual power consumers p 173 Battery discharged Ignition not switched off when vehicle parked Recharge the battery x p 169 Battery is not charged by the alternator Check charging voltage x Combination instrument shows nothing in display Fuse 1 blown Change the fuses of individual power consumers p 173 Speedometer in combination inst...

Page 218: ...link code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink code of immobilizer indica tor lamp 15 Immobilizer indicator lamp flashes 1x short 1 second pause 5x short Error level condition Black ignition key inactive Blink code of immobilizer indica tor lamp 16 Immobiliz...

Page 219: ... indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pause 2x short Error level condition Malfunction in CAN bus communication Blink code of immobilizer indica tor lamp 60 Immobilizer indicator lam...

Page 220: ...mp MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code EFI warning lamp MIL 09 EFI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code EF...

Page 221: ... too low Intake air temperature sensor input signal too high Blink code EFI warning lamp MIL 14 EFI warning lamp MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high Blink code EFI warning lamp MIL 15 EFI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor input signal too l...

Page 222: ...rt Error level condition Power supply circuit fault Blink code EFI warning lamp MIL 25 EFI warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch circuit fault Blink code EFI warning lamp MIL 33 EFI warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code EFI warning lamp MIL 34 EFI warning lamp MIL flashes 3x long 4x s...

Page 223: ... condition Fuel pump controller short circuit to ground or open circuit Fuel pump controller input signal too high Blink code EFI warning lamp MIL 45 EFI warning lamp MIL flashes 4x long 5x short Error level condition Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit Lambda sensor heater cylinder 1 sensor 1 input signal too high Blink code EFI warning lamp MIL 46 EFI...

Page 224: ...IL 53 EFI warning lamp MIL flashes 5x long 3x short Error level condition Fuel evaporation valve short circuit to ground or open circuit Fuel evaporation valve input signal too high Blink code EFI warning lamp MIL 54 EFI warning lamp MIL flashes 5x long 4x short Error level condition Secondary air valve short circuit to ground or open circuit Secondary air valve input signal too high Blink code EF...

Page 225: ...Manifold absolute pressure sensor cylinder 2 connection leaks Blink code EFI warning lamp MIL 81 EFI warning lamp MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code EFI warning lamp MIL 91 EFI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus communication error ...

Page 226: ...d in applicable regulations Info To maintain the value and appearance of the motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle Before cleaning seal the 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 Mot...

Page 227: ...s of the engine and brakes After the engine has cooled down lubricate or grease all moving parts and bearings Clean the chain p 136 Treat bare metal except for brake discs and the exhaust system with an anticorrosive Cleaning and preserving materials for metal rubber and plastic p 247 Treat all painted parts with a mild lacquer care spray Paint cleaner and polish for high gloss and matte finishes ...

Page 228: ...icle has been used on salted roads clean it with cold water Warm water intensifies the effects of salt Clean the motorcycle p 224 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 wit...

Page 229: ...n fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 224 Change the engine oil and filter clean the oil screen x p 204 Check the coolant level p 189 Check the antifreeze x Check the tire pressure p 162 Remove the battery x p 165 Recharge the battery x p 169 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place ...

Page 230: ...ter 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 110 Take the rear from the work stand p 111 Recharge the battery x p 169 Install the battery x p 167 Set the clock with SET CLOCK p 78 Fill up with fuel p 105 Make checks before putting into operation p 97 Take a...

Page 231: ...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 Dry sump lubrication system with three rotor pumps Primary transmission 40 76 Cl...

Page 232: ...k plug NGK LKAR9BI9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 500 1 600 rpm Cold start device Electric 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 244 External temperature 0 C 32 F Engine oil SAE 5W 40 p 244 16 2 Capacity coolant Coolant 2 6...

Page 233: ...rew camshaft bearing support M6 10 9 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Loctite 243 Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm 7 4 lbf ft Screw engine case M6x90 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking l...

Page 234: ...lbf ft Step 2 18 Nm 13 3 lbf ft Screw camshaft bearing support M8 10 9 Step 1 8 5 Nm 6 27 lbf ft Step 2 14 5 Nm 10 7 lbf ft Only applies when using Hex key bit 61229025000 Screw engine case M8 18 Nm 13 3 lbf ft Screw engine console M8 20 Nm 14 8 lbf ft Loctite 243 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 timing chain tensioning ...

Page 235: ... 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 17 Nm 12 5 lbf ft Nut of engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 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...

Page 236: ...in floating disc with radial mount 4 piston calipers Rear Single non floating disc with 2 piston brake caliper Brake discs diameter Front 320 mm 12 6 in Rear 220 mm 8 66 in Brake discs wear limit Front 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 passenger full payload Front 2 5 bar 36 psi Rear 2 9...

Page 237: ...mum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 240 kg 529 lb Maximum permissible total weight 380 kg 838 lb Battery YTZ14S Battery voltage 12 V Nominal capacity 11 2 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 18 1 Lighting equipment Low beam high beam H7 base PX26d 12 V 55 W Parking light W5W base W2 1x9 5d 12 V 5 W Instr...

Page 238: ...0 ZR 17 M C 58W TL Pirelli Diabolo Rosso 190 55 ZR 17 M C 75W TL Pirelli Diabolo Rosso Additional information is available in the Service section under http www ktm com 18 3 Capacity fuel Total fuel tank capacity approx 16 5 l 4 36 US gal Super unleaded ROZ 95 RON 95 PON 91 p 246 Fuel reserve approx 3 5 l 3 7 qt ...

Page 239: ...rt 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer s 405 mm 15 94 in Spring rate Medium standard 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 per fork leg 520 ml 17 58 fl oz Fork oil SAE ...

Page 240: ...ull payload 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 Medium standard 95 N mm 542 lb in Spring length 160 mm 6 3 in ...

Page 241: ...TECHNICAL DATA SHOCK ABSORBER 239 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 245 SAE 2 5 ...

Page 242: ...nted M5 3 5 Nm 2 58 lbf ft Bolt foot brake lever stub M6 10 Nm 7 4 lbf ft Loctite 243 Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw exhaust clamp M6 8 Nm 5 9 lbf ft Screw exhaust heat shield M6 15 Nm 11 1 lbf ft Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw foot brake lever M6 15 Nm 11 1 lbf ft Loctite 243 Screw fuel pump M6 6 Nm 4...

Page 243: ...lebar stub M8 20 Nm 14 8 lbf ft Screw ignition lock M8 25 Nm 18 4 lbf ft 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...

Page 244: ...crew side stand M10 35 Nm 25 8 lbf ft Loctite 243 Rear sprocket bolt M10x1 25 50 Nm 36 9 lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Nut of bell crank on frame M14x1 5 100 Nm 73 8 lbf ft Lambda sensor 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 Bolt front axle M25x1 5 45 Nm 33...

Page 245: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 246: ...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 249 SAE p 249 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 247: ... 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 249 SAE 2 5 Guideline Use only oils that comply with the specified standards se...

Page 248: ...SUBSTANCES 246 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 249: ...ube for road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 ...

Page 250: ...plier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 251: ...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 252: ...ngs 147 front brake checking 148 rear brake checking 151 Brakes 103 Braking 103 C Chain checking 141 checking for dirt 136 cleaning 136 Chain tension adjusting 139 checking 138 Cleaning 224 225 Clutch fluid level checking 192 fluid level correcting 193 Clutch lever 29 adjusting basic position 192 Combination instrument activation and test 36 CHANGE MODE menu 59 73 75 display 37 DISTANCE TO Next Se...

Page 253: ...e RACEODO 55 73 75 TPMS menu 70 74 76 TRIP F RESET menu 65 74 76 UNITS menu 66 74 76 Conservation for winter operation 226 Coolant level checking 189 Cooling system 189 filling compensating tank 190 E Electric starter button 33 Emergency OFF switch 32 Engine running in 94 Engine number 27 Engine oil adding 211 changing 204 draining 204 refilling 209 Engine oil level checking 203 Engine sprocket ch...

Page 254: ...173 H Hand brake lever 29 basic position adjusting 145 Handlebar handlebar height 195 handlebar height adjusting 196 Headlight adjustment adjusting 184 checking 184 Headlight flasher switch 30 Helmet lock 89 attaching to vehicle 165 High beam bulb changing 178 Horn button 31 I Ignition key activating deactivating 185 Ignition lock 32 Immobilizer 33 K Key number 26 Kilometers miles SET KM MILES set...

Page 255: ...ing 209 removing 207 Oil screen cleaning 204 Owner s manual 18 P Parking 104 Parking light bulb changing 181 Passenger footrests 90 Passenger seat mounting 164 removing 164 Play in the throttle cable checking 194 Protective treatment for winter operation 226 Putting into operation advice on first use 93 after storage 228 checks to be made before putting into operation 97 R RACE mode setting 78 Rea...

Page 256: ...eneral 116 compression damping high speed adjusting 117 compression damping low speed adjusting 116 rebound damping adjusting 118 spring preload adjusting 119 Shock absorber part number 28 Side stand 92 Spare parts 8 Starting 98 Steering damper 121 adjusting 121 Steering damper part number 28 Steering lock 32 Stopping 104 Storage 227 Supporting strap 88 T Technical data chassis 234 236 chassis tig...

Page 257: ... 9 Troubleshooting 213 215 Turn signal switch 31 Type label 26 U Use definition 8 V Vehicle identification number 26 Vehicle level 123 front adjusting 124 rear adjusting 126 View of vehicle front left 22 rear right side 24 W Warranty 8 Work rules 9 ...

Page 258: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 12 2009 Photo Mitterbauer 3211524en 3211524en ...

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KTM 2010 1190 RC8, Owner'S Manual

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