KTM 2013 1190 RC8 R JP Owner'S Manual Download Page 243

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ENGINE CONTROL BLINK CODE

241

Blink code EFI warning lamp (MIL)

EFI

warning lamp (

MIL

) flashes 4x long, 1x short

Error level condition

Fuel pump control - short circuit to ground or open circuit
Fuel pump control - input signal too high

Blink code EFI warning lamp (MIL)

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)

EFI

warning lamp (

MIL

) flashes 4x long, 6x short

Error level condition

Lambda sensor heater cylinder 2, sensor 1 - short circuit to ground or open circuit
Lambda sensor heater cylinder 2, sensor 1 - input signal too high

Blink code EFI warning lamp (MIL)

EFI

warning lamp (

MIL

) flashes 4x long, 9x short

Error level condition

Motor drive circuit A - circuit fault

Blink code EFI warning lamp (MIL)

EFI

warning lamp (

MIL

) flashes 5x long

Error level condition

Motor drive circuit B - circuit fault

Summary of Contents for 2013 1190 RC8 R JP

Page 1: ...OWNER S MANUAL 2013 1190 RC8 R EU UK 1190 RC8 R FR 1190 RC8 R JP Art no 3211961en ...

Page 2: ......

Page 3: ...t completely All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for de...

Page 4: ...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: ...e number 21 5 4 Fork part number 21 5 5 Shock absorber part number 22 5 6 Steering damper part number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle grip 24 6 4 Horn button 24 6 5 Light switch 25 6 6 Headlight flasher switch 25 6 7 Turn signal switch 26 6 8 Emergency OFF switch 26 6 9 Electric starter button 27 6 10 Ignition steering lock 27 6 11 Combination instrument 2...

Page 6: ...nu gallons SET GAL US UK 71 6 11 39 Additional functions menu OPTIONS 72 6 11 40 Quick shifter menu OPTION QKSHIFT 73 6 11 41 External temperature display menu OPTION OUTTEMP 74 6 11 42 Tire pressure monitor menu OPTION TPMS 75 6 11 43 Table of functions 76 6 11 44 Table of conditions and menu activation 80 6 11 45 Adjusting the mapping of the engine electronics ENGINE MAP 83 6 11 46 Displaying la...

Page 7: ...bsorber 125 10 7 Adjusting the high speed compression damping of the shock absorber 126 10 8 Adjusting the rebound damping of the shock absorber 127 10 9 Adjusting the spring preload of the shock absorber x 127 10 10 Steering damper 129 10 11 Adjusting the steering damper 130 10 12 Vehicle level 131 10 13 Adjusting front vehicle level x 132 10 14 Adjusting the vehicle level at the rear 134 10 15 F...

Page 8: ...ecking the rear brake fluid level 175 12 8 Adding rear brake fluid x 176 12 9 Checking the rear brake linings 178 13 WHEELS TIRES 179 13 1 Removing the front wheel x 179 13 2 Installing the front wheel x 180 13 3 Removing the rear wheel x 183 13 4 Installing the rear wheel x 184 13 5 Checking rear hub cush drive x 186 13 6 Checking the tire condition 187 13 7 Checking the tire pressure 189 14 ELEC...

Page 9: ...steps for winter operation 229 19 STORAGE 230 19 1 Storage 230 19 2 Putting into operation after storage 231 20 TROUBLESHOOTING 232 21 IMMOBILIZER BLINK CODE 235 22 ENGINE CONTROL BLINK CODE 237 23 TECHNICAL DATA 243 23 1 engine 243 23 2 engine tightening torques 244 23 3 Capacities 248 23 3 1 Engine oil 248 23 3 2 Coolant 248 23 3 3 fuel 248 23 4 chassis 248 23 5 Electrical system 250 23 6 Tires ...

Page 10: ...rstanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 11: ...ads in the homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they ar...

Page 12: ...ken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 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 desig...

Page 13: ...iousness 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 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow ...

Page 14: ...ts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that p...

Page 15: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle ...

Page 16: ... accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are specified in parentheses in the descriptions Your KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM we...

Page 17: ...uipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 3 6 Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can ...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example B01301 10 ...

Page 19: ... Light switch p 25 2 Headlight flasher switch p 25 2 Turn signal switch p 26 2 Horn button p 24 3 Filler cap 4 Tool set p 99 5 Seat lock p 98 6 Oil dipstick 7 Side stand p 102 8 Shift lever p 100 9 Helmet lock p 102 10 Passenger footrests p 100 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example B01302 10 ...

Page 21: ...teering lock p 27 5 Emergency OFF switch p 26 5 Electric starter button p 27 6 Hand brake lever p 23 7 Vehicle identification number type label p 20 8 Shock absorber rebound adjustment 9 Shock absorber compression adjustment 10 Foot brake lever p 101 11 Engine number p 21 12 Throttle grip p 24 13 Fork compression adjustment ...

Page 22: ...me above the vehicle identification number 5 2 Key number 700222 01 The key number Code number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used for learning and programming funct...

Page 23: ...RIAL NUMBERS 21 5 3 Engine number B01304 10 The engine number 1 is stamped on the right side of the engine 5 4 Fork part number B01305 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 24: ...0657 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber above the adjusting ring towards the rear 5 6 Steering damper part number 100658 10 The steering damper part number 1 is stamped on the top of the steering damper ...

Page 25: ...clutch lever 1 is fitted on the left side of the handlebar The clutch is hydraulic and self adjusting 6 2 Hand brake lever 100660 10 The hand brake lever 1 is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 26: ...ottle grip 1 is fitted on the right side of the handlebar 6 4 Horn button 100661 12 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 27: ... 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 6 6 Headlight flasher switch 100662 10 The headlight flasher switch 1 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 ope...

Page 28: ...ed 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 6 8 Emergency OFF switch 100664 10 The emergency OFF switch 1 is installed on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation the ignition circuit is clos...

Page 29: ...r triple clamp Info The ignition may only be switched on using a black ignition key Use the orange programming key to activate and deactivate the black ignition key Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The black ignition key can be removed Ignition ON In this position the ignition circuit is...

Page 30: ...6 CONTROLS 28 6 11 Combination instrument 6 11 1 Overview 401121 10 1 Display p 31 2 Function buttons 3 Indicator lamps p 33 4 Info display p 32 ...

Page 31: ... fitted on the handlebar front left The LAP button 2 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 on the info display in ROAD mode Clocks the lap times in RACE mode ...

Page 32: ...s switched on Test The segments of the tachometer and the gear display 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 The display then changes to the last selected mode ...

Page 33: ...3 shows the engaged gear Info The engaged gear can also be displayed in the info display The speed 4 is displayed in kilometers per hour KM H or in miles per hour MPH The time appears in segment 5 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 6 The info display 7 shows additional informat...

Page 34: ...on 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 35: ... 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 on board diagno sis has detected an emission or safety critical error The general warning lights up yellow An operating safety warning mes sage was detected This is also shown periodically in t...

Page 36: ... 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 from operat ing the vehicle The second black ignition key is activated when the vehicle is shipped Two additional spare ignition keys key number on the KEYCODECARD can be ordered from an authorized...

Page 37: ...ue Battery voltage 10 80 V 401125 01 SERVICE IN xxx KM MPH appears on the info display if the distance to the next service falls below the specified value Distance 500 km 310 7 mi 401166 01 HIGH TEMP appears on the info display if the coolant temperature rises above the specified value Coolant temperature 120 C 248 F ...

Page 38: ...01127 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 39: ...37 ...

Page 40: ...6 CONTROLS 38 6 11 9 Overview of ROAD mode 401128 10 ...

Page 41: ... is on The motorcycle is being ridden ROAD mode Press the MODE button briefly and repeatedly until ODO Trip 1 Time 1 and Avs 1 appear in the info display ODO shows the total distance covered 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 ...

Page 42: ...1130 01 Condition Alternative 1 The ignition is on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is being ridden ROAD mode Press the MODE button briefly and repeatedly until ODO and Trip 2 appear in the info display ODO shows the total distance covered Trip 2 shows the distance covered since the last reset For example between two refueling stops Trip 2 is a...

Page 43: ...lay changes to the SET UP menu Press the MODE but ton for 3 5 sec onds The display of Trip 2 Time 2 and Avs 2 is reset Press the MODE but ton briefly Next display mode 6 11 12 Gear display menu ODO Trip 1 Gear 401131 01 Condition Alternative 1 The ignition is on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is being ridden ROAD mode Press the MODE button br...

Page 44: ...counts up to 9999 9 Gear shows the gear currently engaged 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 The display of Trip 1 Time 1 and Avs 1 is reset Press the MODE but ton briefly Next display mode ...

Page 45: ...el consumption Avg shows the average fuel consumption OutTemp shows the external temperature The external temperature can be switched on and off in the SET UP menu TripF shows the distance covered since the fuel reserve level was reached Info The TripF display only appears after you receive the fuel reserve level Press the button No function Press the button No function Press the button and the bu...

Page 46: ...ess the MODE button briefly and repeatedly until ENGINE MAP appears in the info dis play ENGINE MAP shows the active mapping for the engine electronics Press the button Changes the mapping Press the button Changes the mapping 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 Open and exit ENGINE MAP setting is saved Press...

Page 47: ...ly until DISTANCE TONext 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 48: ...6 CONTROLS 46 6 11 16 Overview of RACE mode 401142 10 ...

Page 49: ...143 01 Condition Alternative 1 The ignition is on The motorcycle is stationary RACE mode Alternative 2 The ignition is on The motorcycle is being ridden RACE mode Press the MODE button briefly and repeatedly until LAPSTOGO appears at the top left of the info display LAPSTOGO shows the number of remaining laps If an R appears after LAPSTOGO the stopwatch is running in the background If a P appears ...

Page 50: ... and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All values in RACE mode are reset except RACEODO Press the MODE but ton briefly Next display mode 6 11 18 Maximum lap speed menu TOPSPEED 401144 01 Condition Alternative 1 The ignition is on The motorcycle is stationary RACE mode Alternative 2 The ignition is on The motorcycle is being ri...

Page 51: ...ximum speed difference between the last lap and the lap before Best shows the maximum speed difference between the last lap and the highest maximum speed If the last lap was the lap with the highest maximum speed the info display shows Best Best Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the...

Page 52: ...fo display LastLap shows the lap time of the last lap RaceTrip shows the distance covered since the last reset For example between two refuel ing stops RaceTrip is always running and counts up to 999 9 Gear shows the gear currently engaged 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 53: ...el consumption Avg shows the average fuel consumption OutTemp shows the external temperature The external temperature can be switched on and off in the SET UP menu TripF shows the distance covered since the fuel reserve level was reached Info The TripF display only appears after you receive the fuel reserve level Press the button No function Press the button No function Press the button and the bu...

Page 54: ...ess the MODE button briefly and repeatedly until ENGINE MAP appears in the info dis play ENGINE MAP shows the active mapping for the engine electronics Press the button Changes the mapping Press the button Changes the mapping 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 Open and exit ENGINE MAP setting is saved Press...

Page 55: ...mber of the lap with the best lap time LapTime shows the time of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press the button The next lap is displayed Press the button The previous lap is displayed Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All values in ...

Page 56: ...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 5 sec onds All...

Page 57: ...ered 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 M...

Page 58: ...EMP OPTION TPMS BACK SET KM MILES SET C F SET FUEL CONS SET GAL US UK BACK SET UP CHANGE MODE SET CLOCK SETTINGS UNITS OPTIONS EXIT SETUP ODO Trip 1 ODO Trip 2 ODO Trip 1 Gear FUEL ENGINE MAP DISTANCE TO Next Service LAPSTOGO TOPSPEED LastLap RaceTrip Gear FUEL ENGINE MAP LAP BESTLAP LapTime LAP BESTLAP TopSpeed RACEODO 401152 01 ...

Page 59: ...6 CONTROLS 57 Settings in SET UP mode Mode menu CHANGE MODE Time menu SET CLOCK Settings menu SETTINGS Units menu UNITS Additional functions menu OPTIONS EXIT SETUP menu ...

Page 60: ...ning light the lap blank time of the LAP button the number of laps and the reset time of the fuel reserve display In the UNITS menu you can set the units for the speed or distance temperature and fuel consumption In the OPTIONS menu you can switch on and off the optional quick shifter the external temperature display and the optional tire pressure monitor Select EXIT SETUP to close the SET UP menu...

Page 61: ... on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the MODE button briefly In 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 MOD...

Page 62: ... the button for 3 5 seconds Press the button once until the symbol shows SET CLOCK in the info display Press the MODE button briefly You can set the clock in 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 the next val...

Page 63: ... menu you can activate the shift warning light In the LAP BLANK TIME menu you can set the lap blank time of the LAP button In the SET NUM LAPS menu you can set the number of laps to cover in RACE mode In the TRIP F RESET menu you can set the reaction time of the fuel reserve display to changes in the fuel level In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu...

Page 64: ...cle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the MODE button briefly In the SHIFT RPMS menu you can activate the shift warning light Press the button Increases the value Press the button...

Page 65: ...ernative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button once until the symbol shows LAP BLANK TIME in the info display Press the MODE button briefly In the LAP BLANK TIME menu you set the lap blank time of the LAP but...

Page 66: ...he motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button twice until the symbol shows SET NUM LAPS in the info display Press the MODE button briefly In the SET NUM LAPS menu you can set the number of laps to cover in RACE mode Press the button Incre...

Page 67: ...ion is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button three times until the symbol shows TRIP F RESET in the info dis play Press the MODE button briefly In the TRIP F RESET menu you can set the reaction time of the fuel reserve display...

Page 68: ...6 CONTROLS 66 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 TRIP F RESET Press the MODE but ton briefly Open and exit TRIP F RESET ...

Page 69: ...for measuring speed and distance In the SET C F menu you can set the unit for the temperature display In the SET FUEL CONS menu you can set the unit liters of the fuel consumption In the SET GAL US UK menu you can set the unit gallons of the fuel consumption In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu can be activated with the MODE button Press the butto...

Page 70: ...tionary RACE mode Press the button and the button for 3 5 seconds Press the button three times until the symbol shows UNITS in the info display Press the MODE button briefly Press the MODE button briefly In 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 ...

Page 71: ...d the button for 3 5 seconds Press the button three times until the symbol shows UNITS in the info display Press the MODE button briefly Press the button once until the symbol shows SET C F in the info display Press the MODE button briefly In 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 th...

Page 72: ...l shows UNITS in the info display Press the MODE button briefly Press the button twice until the symbol shows SET FUEL CONS in the info display Press the MODE button briefly In the SET FUEL CONS menu you can set the unit liters of the fuel consumption 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 t...

Page 73: ...lay Press the MODE button briefly Press the button three times until the symbol shows SET GAL US UK in the info dis play Press the MODE button briefly In the SET GAL US UK menu you can set the unit gallons of the fuel consumption 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 Op...

Page 74: ...OPTION QKSHIFT menu you can switch the optional quick shifter on off In the OPTION OUTTEMP menu you can switch the external temperature display on off In the OPTION TPMS menu you can switch the tire pressure check on off available as accessory In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu can be activated with the MODE button Press the button The arrow mov...

Page 75: ... Press the button and the button for 3 5 seconds Press the button four times until the symbol shows OPTIONS in the info display Press the MODE button briefly Press the MODE button briefly In the OPTION QKSHIFT menu you can switch the optional quick shifter on off Press the button Switches quick shifter on and off Press the button Switches quick shifter on and off Press the button and the button fo...

Page 76: ...e button four times until the symbol shows OPTIONS in the info display Press the MODE button briefly Press the button once until the symbol shows OPTION OUTTEMP in the info display Press the MODE button briefly In the OPTION OUTTEMP menu you can switch the external temperature display on off Press the button Switches external temperature display on and off Press the button Switches external temper...

Page 77: ... button for 3 5 seconds Press the button four times until the symbol shows OPTIONS in the info display Press the MODE button briefly Press the button twice until the symbol shows OPTION TPMS in the info display Press the MODE button briefly In the OPTION TPMS menu you can switch the tire pressure check on off available as accessory Press the button Switches tire pressure display on and off Press t...

Page 78: ...ion The display changes to the SET UP menu The display of Trip 2 Time 2 and Avs 2 is reset Next display mode Gear display menu ODO Trip 1 Gear No function No function The display changes to the SET UP menu The display of Trip 1 Time 1 and Avs 1 is reset Next display mode Fuel and external tem perature menu FUEL No function No function The display changes to the SET UP menu Note LOW FUEL in info di...

Page 79: ...rature menu FUEL No function No function The display changes to the SET UP menu Note LOW FUEL in info display goes out Next display mode Mapping menu ENGINE MAP Changes the map ping Changes the map ping The display changes to the SET UP menu Open and exit ENGINE MAP setting is saved Closes ENGINE MAP setting is not stored Lap times menu LAP BESTLAP LapTime The next lap is dis played The previous l...

Page 80: ... No function The menu in front of the arrow is selected The menu in front of the arrow is selected Shift warning lamp menu SHIFT RPMS Increases the value Decreases the value No function Open and exit SHIFT RPMS or change to the next value Open and exit SHIFT RPMS or change to the next value LAP button blank time LAP BLANK TIME menu Increases the value Decreases the value No function Open and exit ...

Page 81: ...it Changes the unit No function Open and exit SET GAL US UK Open and exit SET GAL US UK Additional functions menu OPTIONS 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 selected Quick shifter menu OPTION QKSHIFT Switches quick shifter on and off Switches quick shifter on and off No function Open and exit OPTION QKSHI...

Page 82: ...n The motor cycle is being ridden RACE mode The ignition is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Distance menu 1 ODO Trip 1 Time 1 Avs 1 Distance menu 2 ODO Trip 2 Time 2 Avs 2 Gear display menu ODO Trip 1 Gear Fuel and external temperature menu FUEL Mapping menu ENGINE MAP N...

Page 83: ...tion is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Maximum lap speed menu TOPSPEED Gear display menu LastLap RaceTrip Gear Fuel and external temperature menu FUEL Mapping menu ENGINE MAP Lap times menu LAP BESTLAP LapTime Maximum speed menu LAP BESTLAP TopSpeed Total distance in Ra...

Page 84: ...e The ignition is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated SETTINGS menu Shift warning lamp menu SHIFT RPMS LAP button blank time LAP BLANK TIME menu Number of laps menu SET NUM LAPS Fuel reserve display menu TRIP F RESET UNITS menu Kilometers miles menu SET KM MILES Temperature ...

Page 85: ...nit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Fuel consumption menu gal lons SET GAL US UK Additional functions menu OPTIONS Quick shifter menu OPTION QKSHIFT External temperature display menu OPTION OUTTEMP Tire pressure monitor menu OPTION TPMS 6 11 45 Adjusting the mapping of the engine electronics ENGINE MAP Note Material d...

Page 86: ...ith the button or the button Press the MODE button for 3 5 seconds The setting is stored 401148 01 Condition RACE mode Press the MODE button briefly and repeatedly until ENGINE MAP appears in the info display Press the MODE button for 3 5 seconds Select the mapping with the button or the button Press the MODE button for 3 5 seconds The setting is stored 6 11 46 Displaying lap times Condition The i...

Page 87: ...isplayed Press the MODE button briefly Next display mode 6 11 47 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE mode 401150 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 displa...

Page 88: ...anges 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 6 11 49 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 butt...

Page 89: ...tationary 400460 01 Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the MODE button briefly RPM1 and RPM2 appear on the info display The engine speed after RPM1 flashes Info The engine speed can be set at intervals of 50 RPM1 is the engine speed above which the shift warning light starts ...

Page 90: ...ettings are stored and the display switches to the SETTINGS 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 6 11 51 Setting the blank time of the...

Page 91: ...ANK TIME function 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 t...

Page 92: ...n briefly TOTAL LAPS appears on 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 switches to the SETTINGS menu Press the button briefly and repeatedly until the symbol s...

Page 93: ...PF RESET appears in the info display with the reaction time Info At delivery TRIPF RESET is set to 300 seconds Set the reaction time of the fuel reserve display with the button or the button Info You can set the TRIPF RESET to between 10 and 1000 seconds in steps of 10 Press the MODE button briefly The settings are stored and the display changes to the SETTINGS menu Press the button briefly and re...

Page 94: ... Press the MODE button briefly Press the MODE button briefly The selected unit appears on the left in 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 a...

Page 95: ... the symbol shows SET C F in the info display Press the MODE button briefly The selected unit appears on the left in 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 b...

Page 96: ... info display Press the MODE button briefly Press the button twice until the symbol shows SET FUEL CONS in the info display Press the MODE button briefly The selected unit appears in the info 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 s...

Page 97: ...lay Press the MODE button briefly Press the button three times until the symbol shows SET GAL US UK in the info dis play Press the MODE button briefly The selected unit appears in the info 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 show...

Page 98: ...ws OPTION OUTTEMP in the info display Press the MODE button 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 MO...

Page 99: ...es rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment ...

Page 100: ...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 6 14 Seat lock B01308 11 The seat lock 1 is behind the seat It can be locked with the ignition key ...

Page 101: ...6 CONTROLS 99 6 15 Tool set 100670 10 The tool set 1 is in the storage compartment under the seat 6 16 Supporting strap B01308 10 The supporting strap 1 is provided for the passenger to hold on to ...

Page 102: ...er 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 6 18 Shift lever B00558 10 The shift lever 1 is mounted on the left of the engine ...

Page 103: ...ositions can be seen in the picture The neutral or idle position N is between the first and second gear 6 19 Foot brake lever B01309 10 The foot brake lever 1 is in front of the right footrest The foot brake lever operates the rear brake ...

Page 104: ...d 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 6 21 Helmet lock B01311 01 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is a...

Page 105: ...erent tire tread patterns 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...

Page 106: ...ver p 170 Adjust the foot brake lever p 143 Adjust the shift lever p 139 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 104 7 2 Running the engine in Do not exceed the speci...

Page 107: ...ng 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 visib...

Page 108: ...ge 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 109: ...ke fluid level p 172 Check the rear brake fluid level p 175 Check the front brake linings p 174 Check the rear brake linings p 178 Check the brake system Check the coolant level p 212 Check the chain for dirt p 161 Check the chain tension p 162 Check the tire condition p 187 Check the tire pressure p 189 Check the adjustment and smooth operation of all controls Check that the electrical equipment ...

Page 110: ... 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 111: ...arting 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 clu...

Page 112: ...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 hold himself or herself properly on the passenger seat The passenger must hold on to the rider or supporting strap firmly and pl...

Page 113: ...the tires 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 i...

Page 114: ...h 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 lower Acc...

Page 115: ...r of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system 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 ...

Page 116: ...two gears but do not race the engine You will require less braking force and the brakes will not overheat 8 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some veh...

Page 117: ...f you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power 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...

Page 118: ...ble Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of ...

Page 119: ... the engine Adjust the mapping of the engine electronics for the fuel quality currently in use 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 B01312 10 Switch off the engine Open the filler cap p 97 Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler Total fuel t...

Page 120: ...rake linings p 178 Check the rear brake disc p 171 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 175 Check the free travel of the foot brake lever p 143 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 co...

Page 121: ...hrottle 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 215 Change the air filter Clean the air filter box x Check the fuel pressure x Check the value of the manifold absolute pressure sensor PM value with the KTM diagnostics tool x Che...

Page 122: ...and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride x Set the service interval display 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 y...

Page 123: ... 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 10 2 Adjusting the compression damping of t...

Page 124: ...rk type Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 10 3 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 energy and ena...

Page 125: ...Rebound damping Comfort 20 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 10 4 Adjusting the spring preload of the fork Info Spring preload determines the initial fork position The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and...

Page 126: ...u should also adjust the rebound damping when you alter the spring preload 10 5 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing af...

Page 127: ...ased to help Info The low speed setting can be seen during the slow to normal compression of the shock absorber 100686 10 Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click Info Do not loosen nut 2 Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 20 clicks Spor...

Page 128: ...p will be pleased to help Info The high speed setting can be seen during the fast compression of the shock absorber B00574 10 Turn adjusting screw 1 clockwise all the way using a socket wrench Info Do not loosen nut 2 Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 3 turns Standard 2 5 turns Sport 1 5 turns...

Page 129: ...e last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 10 9 Adjusting the spring preload of the shock absorber x Warning Danger of accidents Modificat...

Page 130: ...eight off the rear wheel and swingarm Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight Loosen screw 1 by two turns 100690 01 Turn the adjusting ring counterclockwise with the wrench from the tool kit until the spring is no longer under tension Hook wrench 69012022000 Extension 60012060000 Turn the adjusting ring clockwise and te...

Page 131: ... to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel The steering damper is adjusted to suit the riding style and the road conditions For high speeds a setting with high damping can be chosen to make the best possible use of the steering damper function In slow tight bends intensive damping can negatively affect handli...

Page 132: ...towards as far as the last perceptible click Adjust the steering damper according to your riding style and the road conditions 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...

Page 133: ...f the fork leg clamp and at the rear by the eccentric shaft The fork legs can be clamped at three positions in the triple clamp 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 infinitely variable frame height setting can be adjusted by tu...

Page 134: ... screw 3 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 100695 01 Align the fork leg in the desired position by means of the fork rings Guideline Upper triple clamp flush with upper e...

Page 135: ...e to become more stable but also more difficult to handle 100694 10 Tighten screw 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 1 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Tighten screw 3 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 136: ...ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior 100696 10 Loosen screw 1 100697 10 Turn eccentric shaft 2 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 137: ...ystem 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 10 16 Adjusting the footrest position Info The footrest position must be identical on the left and the right ...

Page 138: ...th spacers 2 and screws Guideline Standard Upper position Info The adjustable footrest bracket enables a more comfortable lower footrest posi tion or a sporting upper footrest position B00561 01 Mount and tighten the screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 ...

Page 139: ...10 TUNING THE CHASSIS 137 100702 01 Repeat adjustment work on the footrest bracket on the other side Adjust the shift lever p 139 Adjust the foot brake lever p 143 ...

Page 140: ...3 10 Remove the screw 1 with the shift lever stub Position the shift lever stub with the screw in one of the holes 2 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 ...

Page 141: ...brake lever stub with the screw in one of the holes 2 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 10 19 Adjusting shift lever Info The footrest system offers many ways of adjusting the shift lever to your riding style and requirements ...

Page 142: ...ve screws 1 and take off the shift rod Loosen lock nuts 2 Adjust the shift rod Guideline Shift rod adjustment range 114 153 mm 4 49 6 02 in Info Make the same adjustments on both sides At least 5 screw threads must be screwed into the seating ...

Page 143: ...t lever lower drill hole shift shaft lower drill hole Shift power high short shift travel C shift lever lower drill hole shift shaft upper drill hole Info The shift rod can be mounted both on the shift lever variably at an upper or lower position and on the reverse gear change of the shift shaft in two differ ent positions Mount and tighten the screws Guideline Screw shift rod M6 12 Nm 8 9 lbf ft ...

Page 144: ... or a low position of the shift lever E Tighten the lock nuts of the shift rod Info 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 Check the shift lever to ensure it is functioning properly and can move freely Guideline The moving parts of the shift lever m...

Page 145: ...and the hex nut is locked 100708 10 Check the foot brake lever setting Info Position A of the foot brake lever may vary considerably depending on the set ting 10 21 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 Adjus...

Page 146: ...in the process If the free travel does not meet specifications Adjust the free travel 10 22 Handlebar height position 100755 10 Handlebar height By removing or inserting distance sleeve 1 you can set the handlebar height to two differ ent positions Length distance sleeve 15 mm 0 59 in With distance sleeves the handlebar stub is positioned low for sports use Removing the distance sleeves gives a mo...

Page 147: ... position difference 6 5 Standard Position A 10 23 Adjusting the handlebar height position Info The handlebar stub position must be identical on the left and right of the vehicle 100756 11 Adjusting the high position of the handlebar stubs Loosen screw 1 Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw 2 ...

Page 148: ...above the triple clamp Mount and tighten screw Guideline Remaining frame bolts M5 5 Nm 3 7 lbf ft 100759 01 Tighten the screw Guideline Screw handlebar stub M8 20 Nm 14 8 lbf ft Repeat the adjustments on the other handlebar stub Move the handlebar to and fro over the entire steering range If the cables restrict the freedom of movement of the steering Correct the cable routing If a component restri...

Page 149: ...0 Remove screw 2 with distance sleeve 3 Carefully shift the handlebar stub by the length of the distance sleeve Watch out for the handlebar position difference Guideline Length distance sleeve 15 mm 0 59 in Handlebar position difference 6 5 Lay all cables between the upper triple clamp and the handlebar stub Position the distance sleeve Mount and tighten screw Guideline Remaining frame bolts M5 5 ...

Page 150: ...he cable routing If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986 11 Adjusting the narrow position of the handlebar stubs Loosen screw 1 Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw 2 with distance sleeve Carefu...

Page 151: ...er the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986 10 Adjusting the wide position of the handlebar stubs Loosen screw 1 Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw 2 with distance sle...

Page 152: ...bar stub Carefully move the handlebar to and fro over the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 10 24 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 A 8...

Page 153: ...ations ride slowly at first to get the feel of the new ride behavior Preparatory work Remove the seat p 158 B01317 10 Main work Remove screws 1 with the bushings B01318 10 Raising the seat position Remove screws 2 with the washers on the left and right sides of the vehicle Push down on the subframe until the drilled holes of the frame are aligned with the holes at the bottom front of the subframe ...

Page 154: ...B01318 11 Remove screws 3 with the washers on the left and right sides of the vehicle Push up on the subframe until the drilled holes of the frame are aligned with the holes at the bottom rear of the subframe B01318 12 Tighten screws 3 on the left and right sides of the vehicle Guideline Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 ...

Page 155: ...Mount the screws with the washer on the left and right sides of the vehicle but do not tighten yet B01318 14 Remove screws 2 with the washers on the left and right sides of the vehicle Push up on the subframe until the drilled holes of the frame are aligned with the holes at the top front of the subframe B01319 01 Mount and tighten the screws with the washers on the left and right sides of the veh...

Page 156: ... Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 Info Check the cable routing the lambda sensor cable should not be taut 305720 10 Mount rubber cover 4 in the vacant threaded holes on both sides B01317 11 Position bushings 5 Mount and tighten screws 1 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 157: ...10 TUNING THE CHASSIS 155 Finishing work Fit the seat p 159 ...

Page 158: ...t the rear Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear to the link fork and the adapters and raise the motorcycle 11 2 Removing the rear of motorcycle from the lifting gear 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 ...

Page 159: ...in work Move the handlebar to the straight ahead position Align the lifting gear at the front with the adapters to the fork legs Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise the motorcycle at the front 11 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a fi...

Page 160: ... work Release bleeder screws 1 Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Info Perform this action on both fork legs 11 6 Removing the seat B01308 11 Insert the ignition key in the seat lock 1 and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards ...

Page 161: ...e 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 journey Always remove the helmet lock before start ing out B01324 10 Remove the seat p 158 Position the steel cable from the tool kit with one loop on the lug 1 Steel cable 60012015000 Guide...

Page 162: ... the passenger seat B01326 01 Warning 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 Position the passenger seat in the space provided Press down the passenger seat until it clicks into place Finally check that the passenger seat is correctly mounted ...

Page 163: ...eir grip Remove oil and grease with a suitable cleaning material 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 Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disp...

Page 164: ...ning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose ...

Page 165: ...sion p 163 11 14 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission ca...

Page 166: ...e reference marks C 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 2 Make sure that the chain adjusters 4 are on the adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of th...

Page 167: ...ain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 168: ... Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is greater than the specified measurement Change the power set 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 safet...

Page 169: ...ets 1 of the chain are no longer visible at the lower edge C of the opening of the chain sliding guard Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm 3 7 lbf ft ...

Page 170: ...andlebar 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 11 17 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fl...

Page 171: ...169 11 18 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 100753 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 259 Refit the sc...

Page 172: ...nger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM RC8 workshop will 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 A Info Wear reduces the thickness of the brake discs in area 1 of the brake discs Brake discs wear limit Front ...

Page 173: ... Your authorized KTM RC8 workshop will be pleased to help 400480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment A Info Wear reduces the thickness of the brake disc in area 1 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 damag...

Page 174: ... and rear brake according to the service schedule Your authorized KTM RC8 workshop will be pleased to help 100712 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the brake fluid reservoir 1 If the brake fluid is below the MIN marking Add front brake fluid x p 172 12 5 Adding brake fluid of front brake x Warning Danger of accidents ...

Page 175: ... rear brake 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 seals and brake lines are not d...

Page 176: ...id immediately with water 12 6 Checking the front brake 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 carrier...

Page 177: ...linings x 12 7 Checking the rear brake fluid 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 efficiency due to old...

Page 178: ...nd 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 comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warnin...

Page 179: ...lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 178 B01337 10 Main work Stand the vehicle upright Remove screw cap 1 with membrane 2 Add brake fluid to the MAX level Brake fluid DOT 4 DOT 5 1 p ...

Page 180: ...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 destroyed Check the brake linings regularly 100718 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the ...

Page 181: ...ake calipers carefully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake calipers are removed C00335 10 Loosen screws 2 and 3 Release screw 2 by about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw 2 Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always...

Page 182: ...2 Installing the front wheel x C00336 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing x Clean and grease the shaft seal rings 1 and mating surfaces A of the spacers Long life grease p 262 ...

Page 183: ...nd side when viewed in the direction of travel B00584 10 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 Clean screw 3 and axle 4 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw 3 Guideline Bolt front ...

Page 184: ...rake lever while it is actu ated The brake calipers align themselves Tighten screws 5 on both brake calipers Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Release the fixation of the hand brake lever Take the motorcycle off of the front wheel stand p 157 Remove the rear of the motorcycle from the lifting gear p 156 B00581 11 Pull the front brake and compress the fork p...

Page 185: ...ossible and then remove the chain from the rear sprocket Info Protect the motorcycle and its attachments against damage by covering them Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Take the rear wheel out of the swingarm carefully without damaging the rim or brake disc Info Do not op...

Page 186: ...ear brake After installing the rear wheel always operate the foot brake until the pressure point is reached C00341 10 Main work Check the rear hub cush drive x p 186 Remove spacer 1 Clean and grease the mating surfaces of the spacers and the shaft seal rings Long life grease p 262 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing x Instal...

Page 187: ...mpletely to the rear Position the rear wheel The brake caliper support and brake linings are correctly positioned C00344 01 Push the rear wheel as far forward as possible and place the chain on the rear sprocket Pull the rear wheel back and insert the wheel spindle ...

Page 188: ...M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the rear of the motorcycle from the lifting gear p 156 Check the chain tension p 162 13 5 Checking rear hub cush drive x Info The engine power is transmitted by the rear sprocket to the rear wheel through fiv...

Page 189: ...of the shock absorbers Finishing work Install the rear wheel x p 184 Remove the rear of the motorcycle from the lifting gear p 156 Check the chain tension p 162 13 6 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire In the interest of safety replace damaged or worn tires immediately Your authorized KTM RC8 workshop will be pleased t...

Page 190: ...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 exhibit cuts r...

Page 191: ...fter five years If a tire is more than five years old Change the tires 13 7 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 Tire air pre...

Page 192: ...13 WHEELS TIRES 190 Mount the dust cap Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is defective ...

Page 193: ...lames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician 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 dis...

Page 194: ...nect negative minus cable 1 of the battery B01329 10 Remove the cover of the positive terminal Disconnect the positive plus cable 2 of the battery B01329 11 Remove screws 3 Removing the securing bracket 4 Pull the battery up and out of the battery rack ...

Page 195: ...y in the battery rack Info The terminals of the battery must face the rear of the vehicle Position the bracket 1 B01329 13 Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Reconnect the positive plus 3 cable of the battery Position cover of the positive terminal ...

Page 196: ...ttery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries with...

Page 197: ...f the charging current charging voltage and charging time are exceeded electrolyte 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...

Page 198: ...the alternator With this device you cannot overcharge the battery Info Never remove lid 1 Charge the battery at no more than 10 of the capacity specified on the battery housing 2 Switch off the charger after charging Reconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Finishin...

Page 199: ...an be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the seat Preparatory work Switch off all power consumers and the engine Remove the seat p 158 ...

Page 200: ...main fuse 2 Info A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109130 p 250 Tip Place the spare fuse in the starter relay so that it is available if needed Attach the protection covers 1 Finishing work Fit the seat p 159 Set the clock with SET CLOCK p 86 ...

Page 201: ...erloaded if the wrong fuses are used 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 Preparatory work Switch off all power consumers and the engine Remove the seat p 158 B01331 10 Main work Open fuse box cover 1 ...

Page 202: ...se plate lamp Fuse 3 10 A horn brake light Fuse 4 10 A radiator fan Fuse 5 10 A fuel pump Fuse 6 10 A ignition fuel injection Fuse 7 not used Fuse 8 10 A for auxiliary equipment permanent positive Fuse 9 10 A for auxiliary equipment accessories connected to the ignition switch Fuse 10 not used Fuse SPARE 10 A 15 A spare fuses Use spare fuses with the correct rating only Fuse 75011088010 p 250 Fuse...

Page 203: ...uced brightness 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 Preparatory work Switch off all power consumers and the engine 100742 10 Main work Fold up the combination instrument Pull the lug 1 out of the rubber retainer 2 Remove the rubber retainer ...

Page 204: ...he retaining clamp 6 on both sides squeeze and fold to the side Remove headlight bulb 7 700296 01 Position the new headlight bulb in the headlight housing Low beam high beam H7 base PX26d p 250 Info Insert the headlight bulb so that the lug 8 is positioned in the cut out Position the retaining clamp Position the plug in connector ...

Page 205: ... Position the lug 9 of the lamp cover in the notch Engage the latch 3 Check that the lighting is functioning properly 100742 10 Position the rubber holder 2 Fold down the combination instrument Position the lug 1 in the rubber retainer ...

Page 206: ...se 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 Preparatory work Switch off all power consumers and the engine B01332 10 Main work Remove screws 1 Remove the cover 100746 10 Release the latch 2 Remove the lamp cover 3 ...

Page 207: ... 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 250 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 208: ...ver in the notch Engage the latch Check that the lighting is functioning properly B01332 10 Position the cover Info Check for correct positioning and freedom of movement of the brake lines Mount and tighten screws 1 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 209: ...distance A in front of the wall and switch on the low beam Guideline Distance A 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 between light ...

Page 210: ...e headlight range 14 10 Activating deactivating ignition key Info The orange programming key must only be used for activating and deactivating 401114 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 fr...

Page 211: ...h The immobilizer indicator lamp lights up switches off briefly and switches on again Switch off the ignition by turning the black programming key to the position OFF Remove the black 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...

Page 212: ... 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 the orange programming key In this case once since all black ignition keys are deacti vated Switch off the ignition by turning the orange pro...

Page 213: ...ghts up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and switches on again Switch off the ignition by turning the black programming key to the position OFF Remove the black ignition key To activate further ignition keys repeat the last 4 steps with the respective ignition key Insert the orange programming key in the ignition lock Switch on the...

Page 214: ...e compensating tank 3 When the temperature falls this surplus coolant is sucked back into the cooling system 401167 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 15 2 Checking the coolant level Warning Danger of scalding During motorcycle ...

Page 215: ...oolant 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 213 15 3 Filling cooling system compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap ...

Page 216: ...Engine 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 B01333 10 Check the coolant level p 212 Remove...

Page 217: ...ecifications Adjust the play in the throttle cable x p 216 Danger Danger of poisoning Exhaust gases are toxic 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 handleb...

Page 218: ...ion Throttle position sensor circuit A check in zero position x Info It is imperative to use the KTM diagnostics tool for this Push back protective cover 1 Loosen lock nut 2 Set the play in the throttle cable by turning adjusting screw 3 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 2 Mount the protection cap ...

Page 219: ...right on a horizontal surface 100769 10 Main work Remove oil dipstick 1 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 A of the measurement range of the oil dipstick If the engine oil level is not at the specified level Add engine oil p 225 Replace the oil dipstick ...

Page 220: ...ing 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 Drain t...

Page 221: ... off the left exhaust cover 2 100772 10 Stand the motorcycle on its side stand on a level surface Place a suitable container under the engine Remove oil drain plug 3 with the magnet O rings and oil screen Remove the oil filter x p 221 Completely drain the engine oil ...

Page 222: ...73 10 Thoroughly clean magnet 4 and oil screen 5 of the oil drain plug 100772 11 Mount and tighten the oil drain plugs with the magnet O rings and oil screen Guideline Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Install the oil filter x p 223 ...

Page 223: ...crews 1 Guideline Screw painted trim parts M5 3 5 Nm 2 58 lbf ft 17 4 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 224: ...be disposed of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100774 10 Main work Remove screws 1 Take off oil filter cover 2 with the O ring 100775 10 Pull oil filter 3 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Clean the parts and the sealing area thoroughly ...

Page 225: ...ning engine screws M5 6 Nm 4 4 lbf ft 17 6 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine B01336 10 Main work 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 258 External temperature 0 C 32 F Engine oil SAE 5W 40 p 258 Remove the dipstick 1 and top up th...

Page 226: ... 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 Remove the dipstick 1 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 ...

Page 227: ...ystem Start the engine and check that it is oil tight Finishing work Check the engine oil level p 217 17 7 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine Preparatory work Stand the motorcycle upright on a horizontal surface Check the engine oil level p 217 B01336 10 Main work Remove the dipstick 1 and add engine oil Condition Externa...

Page 228: ...Danger Danger of poisoning Exhaust gases are toxic 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 check that it is oil tight Finishing work Check the engine oil level p 217 ...

Page 229: ...leaners brake fluid etc should be disposed of as stipulated 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 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle spray of water Spray very dirty parts with a normal com...

Page 230: ...to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 161 Treat bare metal except for brake discs and the exhaust system with an anticorrosive Cleaning and preserving materials for metal rubber and plastic p 261 Treat all painted parts with a mild paint care product Paint cleaner and polish for high gloss and matte finishes bare metal and plasti...

Page 231: ...ean the brake system Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down while they are installed use cold water and dry them well After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 232: ...refuel before taking the motorcycle out of service Fuel additive p 261 Ride the motorcycle until the LOW FUEL message appears in the info display so that you can fill up with fresh fuel when you take the motorcycle back into service Clean the motorcycle p 227 Change the engine oil and filter clean the oil screen x p 218 Check the coolant level p 212 Check the antifreeze x Check the tire pressure p...

Page 233: ... the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Putting into operation after storage 401059 01 Take the motorcycle off of the front wheel stand p 157 Remove the rear of the motorcycle from the lifting gear p 156 Recharge the battery x p 194 Install the battery x p 193 S...

Page 234: ...bilizer 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...

Page 235: ...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 212 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 199 Defect in radi...

Page 236: ...ke light and horn do not work Fuse 3 blown Change the fuses of individual power consumers p 199 Battery discharged Ignition not switched off when vehicle parked Recharge the battery x p 194 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 199 Speedometer in combination ins...

Page 237: ... Blink 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 Immobil...

Page 238: ...r 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 la...

Page 239: ... lamp 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...

Page 240: ...l 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 ...

Page 241: ...ort Error level condition Gear position sensor circuit fault Blink code EFI warning lamp MIL 24 EFI warning lamp MIL flashes 2x long 4x short 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...

Page 242: ...ition Ignition coil 1 cylinder 1 circuit fault Blink code EFI warning lamp MIL 38 EFI warning lamp MIL flashes 3x long 8x short Error level condition Ignition coil 1 cylinder 2 circuit fault Blink code EFI warning lamp MIL 39 EFI warning lamp MIL flashes 3x long 9x short Error level condition Ignition coil 2 cylinder 1 circuit fault Blink code EFI warning lamp MIL 40 EFI warning lamp MIL flashes 4...

Page 243: ...ound or open circuit Lambda sensor heater cylinder 1 sensor 1 input signal too high Blink code EFI warning lamp MIL 46 EFI warning lamp MIL flashes 4x long 6x short Error level condition Lambda sensor heater cylinder 2 sensor 1 short circuit to ground or open circuit Lambda sensor heater cylinder 2 sensor 1 input signal too high Blink code EFI warning lamp MIL 49 EFI warning lamp MIL flashes 4x lo...

Page 244: ...Error level condition Manifold absolute pressure sensor cylinder 1 connection leaks Blink code EFI warning lamp MIL 69 EFI warning lamp MIL flashes 6x long 9x short Error level condition 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 cod...

Page 245: ...at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston pin bearing No bearing bushes DLC coated piston pins Piston Forged light alloy Piston ring 1 upper compression rectangular ring 1 lower compression ring 1 oil scraper ring Engine lubrication Dry sump lubrication system with three rotor ...

Page 246: ...ide spark plug NGK LMAR7A 9 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 23 2 engine tightening torques Screw damping plate clutch cover EJOT Altracs M6x10 10 Nm 7 4 lbf ft Loctite 243 Screw retaining bracket valve cover rear EJOT Altracs M6x10 10 Nm 7 4 lbf ft H...

Page 247: ...ft Screw clutch spring M6 12 Nm 8 9 lbf ft 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 lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil pump cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift ...

Page 248: ...ring 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 rail M8 15 Nm 11 1 lbf ft Loctite 243 Stud exhaust...

Page 249: ... Nm 22 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 15 Nm 11 1 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 ...

Page 250: ... qt Coolant p 257 Coolant mixed ready to use p 257 23 3 3 fuel Total fuel tank capacity approx 16 5 l 4 36 US gal Super unleaded ROZ 95 RON 95 PON 91 p 260 Super unleaded ROZ 98 RON 98 PON 94 p 260 Fuel reserve approx 3 5 l 3 7 qt 23 4 chassis Frame Lattice frame made of chromium molybdenum steel tubing powder coated Fork WP Suspension Up Side Down 4354 Shock absorber WP Suspension 4014 VP Suspens...

Page 251: ... Front 4 5 mm 0 177 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 bar 42 psi Secondary drive 17 38 Chain 5 8 x 5 16 X ring Steering head angle 66 7 Wheelbase 1 425 mm 56 1 in Seat height unloaded Lower frame rear position 805 mm 31 69 in Upper frame rear posit...

Page 252: ...le total weight 380 kg 838 lb 23 5 Electrical system 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 Low beam high beam H7 base PX26d 12 V 55 W Parking light LED Instrument lights and control lamps LED Turn signal LED Brake tail light LED License plate lamp W5W base W2 1x9 5d 12 V 5 W ...

Page 253: ...vailable in the Service section under http www ktm com 23 7 fork Fork part number 05 18 7K 07 Fork WP Suspension Up Side Down 4354 Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 20 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns ...

Page 254: ... Fork oil per fork leg 500 ml 16 9 fl oz Fork oil SAE 5 p 259 23 8 shock absorber Shock absorber part number 17 18 7K 07 Shock absorber WP Suspension 4014 VP Compression damping high speed Comfort 3 turns Standard 2 5 turns Sport 1 5 turns Full payload 1 5 turns Compression damping low speed Comfort 20 clicks Standard 20 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 20 clic...

Page 255: ...ure 10 bar 145 psi Static sag 11 15 mm 0 43 0 59 in Riding sag 28 35 mm 1 1 1 38 in Inbuilt length 290 mm 11 42 in Shock absorber oil p 259 SAE 2 5 23 9 Chassis tightening torques Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 243 Remaining frame bolts M5 5 Nm 3 7 lbf ft Screw brake fluid reservoir of rear brake M5 5 Nm 3 7 lbf ft Loctite 243 Screw brake line holder M5 5 Nm 3 7 lbf ft Screw ch...

Page 256: ...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 4 lbf ft Screw mirror bracket M6 6 Nm 4 4 lbf ft Screw shift lever stub M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift rod M6 12 Nm 8 9 lbf ft Loctite 243 Screw shift shaft deflector on chain securing guide M6 7 Nm 5 2 lbf ft Loctite 243 Screw shift shaf...

Page 257: ...st bracket M8 25 Nm 18 4 lbf ft Screw rear footrest bracket footrest bracket not mounted M8x25 15 Nm 11 1 lbf ft Screw shift lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 15 Nm 11 1 lbf ft Loctite 243 Screw steering damper clamp on con sole M8 20 Nm 14 8 lbf ft Loctite 243 Screw steering damper fixing b...

Page 258: ...ocket 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 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft...

Page 259: ...ex 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 u...

Page 260: ...orresponding 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 263 SAE p 263 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 Suppli...

Page 261: ...ulic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard 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 263 SAE 2 5 Guideline Use only oils that comply with the specified standards s...

Page 262: ...eaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded ROZ 98 RON 98 PON 94 According to DIN EN 228 ROZ 98 RON 98 PON 94 ...

Page 263: ...n lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer ...

Page 264: ...er Guideline KTM recommends Motorex products Supplier 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 Synthetic ...

Page 265: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In 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 266: ...e linings front brake checking 174 rear brake checking 178 Brakes 113 Braking 113 C Capacity coolant 248 engine oil 223 248 fuel 117 248 Chain checking 165 checking for dirt 161 cleaning 161 Chain tension adjusting 163 checking 162 Clutch fluid level checking 168 fluid level correcting 169 Clutch lever 23 adjusting basic position 168 Combination instrument activation and test 30 additional functio...

Page 267: ...HANGE MODE 59 78 81 next service menu DISTANCE TO Next Service 45 76 80 notes warnings 34 number of laps menu SET NUM LAPS 64 78 82 quick shifter menu OPTION QKSHIFT 73 79 83 remaining laps menu LAPSTOGO 47 77 80 SETTINGS menu 61 78 82 SET UP menu 58 78 81 shift warning lamp menu SHIFT RPMS 62 78 82 temperature display menu SET C F 69 79 82 time menu SET CLOCK 60 78 81 tire pressure monitor menu O...

Page 268: ... part number 21 Front wheel installing 180 removing 179 Fuel consumption unit gallons SET GAL US UK setting 95 liters SET FUEL CONS setting 94 Fuel reserve display TRIP F RESET setting 91 Fuse individual power consumers changing 199 H Hand brake lever 23 basic position adjusting 170 Handlebar handlebar height 144 handlebar height adjusting 145 handlebar position 144 handlebar position adjusting 14...

Page 269: ... MAP adjusting 83 Maximum speed displaying 85 Motorcycle cleaning 227 raising the front with lifting gear 157 raising the rear with lifting gear 156 removing the front from the lifting gear 157 removing the rear from the lifting gear 156 N Number of laps SET NUM LAPS setting 90 O Oil filter changing 218 installing 223 removing 221 Oil screen cleaning 218 Oil screens cleaning 218 Operating substanc...

Page 270: ...tarting off 109 ROAD mode adjusting 86 S Safe operation 11 Seat fitting 159 removing 158 Seat lock 98 Service 14 Service schedule 118 120 SET C F temperature unit setting 93 SET CLOCK adjusting 86 Shift lever 100 setting 139 Shift lever stub adjusting 138 Shift speed RPM1 2 adjusting 87 Shifting 110 Shock absorber 121 compression damping general 124 compression damping high speed adjusting 126 com...

Page 271: ...ine 243 engine tightening torques 244 fork 251 shock absorber 252 tires 251 Throttle grip 24 Tire air pressure checking 189 Tire condition checking 187 Tool set 99 Transport 115 Troubleshooting 232 234 Turn signal switch 26 Type label 20 U Use definition 9 V Vehicle identification number 20 Vehicle level 131 front adjusting 132 rear adjusting 134 View of vehicle front left 16 rear right 18 W Warra...

Page 272: ... 3211961en 3211961en 11 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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