OWNER'S MANUAL 2008 1190 RC8 EU 1190 RC8 AUS/UK 1190 RC8 FR 1190 RC8 JP ART. NO.
DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR KTM CUSTOMER We wish you great pleasure riding the vehicle! Please enter the serial numbers of your vehicle below. Chassis number/type label ( Engine number ( Key number ( S. 16) Dealer's stamp S. 17) S.
DEAR KTM CUSTOMER 2 © 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
CONTENTS CONTENTS MEANS OF REPRESENTATION ............................................... 7 IMPORTANT NOTES ............................................................... 8 VIEW OF VEHICLE................................................................ 12 View of vehicle, front left side............................................ 12 View of vehicle, rear right side ........................................... 14 LOCATION OF SERIAL NUMBERS .........................................
CONTENTS Setting number of laps SET NUM LAPS.............................. Setting fuel reserve display TRIPF RESET........................... Setting kilometers/miles SET KM/MILES............................. Setting temperature unit SET °C/°F .................................... Switching external temperature display on/off...................... Opening the filler cap ....................................................... Closing the filler cap.........................................................
CONTENTS 5 Adjusting shift lever........................................................ Adjusting the footbrake pedal stub ................................... Adjusting the footbrake pedal .......................................... checking for chain dirt .................................................... Cleaning the chain.......................................................... Checking the chain tension ............................................. Adjusting the chain tension ......................
CONTENTS 6 Fitting oil filter .......................................................... Filling up with engine oil ............................................ Topping up engine oil ..................................................... TROUBLESHOOTING.......................................................... IMMOBILIZER FLASH CODE ............................................... ENGINE CONTROL FLASH CODE......................................... CLEANING.....................................................
MEANS OF REPRESENTATION MEANS OF REPRESENTATION 1 Symbols used The following explains the meaning of specific symbols. Identifies an expected reaction (e.g. of an operation or a function). Identifies an unexpected reaction (e.g. of an operation or a function). All jobs marked with this symbol require specialist knowledge and technical understanding.
IMPORTANT NOTES 8 IMPORTANT NOTES 2 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for use on dirt roads. Info The motorcycle is authorized for public road traffic in the homologous version only. Maintenance A prerequisite for fault-free operation and avoiding premature wear is compliance with the maintenance, care and adjustments to the engine and chassis described in the service manual.
IMPORTANT NOTES 9 You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com Work rules During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
IMPORTANT NOTES 10 notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If these are removed, you or other persons may not recognize potential danger and therefore be liable to injury. Grades of risks Danger Danger of leading to immediate, certain, serious, permanent injuries or death. Warning Danger of probable, serious, permanent injuries or death.
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VIEW OF VEHICLE 12 VIEW OF VEHICLE 3 View of vehicle, front left side 3.
VIEW OF VEHICLE 1 Clutch lever 2 Light switch, headlight flasher switch, indicator switch, horn button 3 Filler cap 4 Seat 5 Seat lock 6 Oil dipstick 7 Side stand 8 Shift lever 9 Passenger footrests 13
VIEW OF VEHICLE 14 View of vehicle, rear right side 3.
VIEW OF VEHICLE 1 Passenger seat 2 Supporting strap 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch, electric starter button 6 Hand brake lever 7 Chassis number, type label 8 Rear brake caliper 9 Foot brake pedal 10 Engine number 11 Brake calipers, front 15
LOCATION OF SERIAL NUMBERS 16 LOCATION OF SERIAL NUMBERS 4 Chassis number/type label 4.1 The chassis number is stamped on the frame behind the steering head on the right. The type label is on the frame above the chassis number. 700231-01 Key number 4.2 The key number Code number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key.
LOCATION OF SERIAL NUMBERS Engine number 4.3 The engine number is stamped on the right side of the engine. 700223-01 Fork part number 4.4 The fork part number is stamped on the inner side of the fork stub.
LOCATION OF SERIAL NUMBERS Shock absorber part number 4.5 The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring towards the rear. 700225-01 Steering damper part number 4.6 The steering damper part number is stamped on the top of the steering damper.
OPERATING ELEMENTS 19 OPERATING ELEMENTS 5 Clutch lever 5.1 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulic and self-adjusting. 700227-01 Hand brake lever 5.2 The handbrake lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake.
OPERATING ELEMENTS 20 Light switch 5.3 The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. In this position, the low beam, the high beam and the tail light are switched on. 700230-13 Headlight flasher switch 5.4 The headlight flasher switch is fitted on the left side of the handlebar.
OPERATING ELEMENTS 21 Flasher switch 5.5 The flasher switch is fitted on the left side of the handlebar. Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. To switch off the flasher light, press the flasher switch towards the switch case.
OPERATING ELEMENTS 22 Ignition/steering lock 5.7 The ignition/steering lock is located in front of the upper triple clamp. 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 closed, and the engine can be started. Steering locked – In this position, the ignition circuit is interrupted and the steering locked.
OPERATING ELEMENTS 23 Electric starter button 5.9 The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button 700229-12 in neutral position pressed – In this position, the electric starter is operated.
OPERATING ELEMENTS 24 Combination instrument - overview 5.10 400430-10 1 display ( S. 27) 2 Function buttons 3 Indicator lamps ( 4 info display ( S. 29) S.
OPERATING ELEMENTS 25 Combination instrument - function buttons on handlebar 5.11 The Mode button is fitted on the handlebar, front left. The Lap button is fitted on the handlebar, rear left.
OPERATING ELEMENTS 26 Combination instrument - activation and test 5.12 Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer light up in and switch off in sequence. The speed display counts from 0 to 300 and back. The remaining display segments outside the info display light up briefly. The KTM logo appears in the info display. In ROAD mode, the info display switches to ODO, TripDist, TripTime, AvgSpeed mode.
OPERATING ELEMENTS 27 display 5.13 The The The The tachometer displays the engine speed in revolutions per minute (RPM). red marking marks the over-rev (excessive speed) range of the engine. speed is displayed in kilometers per hour km/h or in miles per hour Mph. time appears in segment . Info After reconnecting the battery or changing the fuse, the time must be reset. The coolant temperature is shown in degrees Celsius or Fahrenheit in segment . The info display shows additional information.
OPERATING ELEMENTS 28 info display 5.14 The info display has two menus. Menu 1 is ROAD mode (standard) for riding on public roads. Menu 2 is RACE mode for riding on race courses. It allows riders to time laps themselves. If the general warning lamp lights up, the corresponding message is shown periodically in the info display. Information repeat 45 s The information shown in the info display can be controlled with the function buttons.
OPERATING ELEMENTS 29 Indicator lamps 5.15 Possible states The flasher indicator lamp flashes green in same rhythm as the flasher. – The flasher is switched on. The oil indicator lamp lights up red – The oil pressure is too low. The shift warning light shows/flashes red – The set shift speed is reached. The idling speed indicator lamp lights up green – The gearbox is in neutral. The high beam indicator lamp lights up blue – The high beam is on.
OPERATING ELEMENTS 30 Notes/warnings on the combination instrument 5.16 LOW FUEL appears on the info display if the minimum range falls below the specified value. Distance 25 km (15.5 mi) 400476-01 LOW BATTERY appears on the info display if the battery voltage falls below the specified value. Battery voltage 400471-01 10.
OPERATING ELEMENTS 31 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) 400472-01 HIGH TEMP appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 120 °C (248 °F) 400474-01 FRONT SENSOR appears on the info display if the coolant temperature sensor of the front cyclinder is defective.
OPERATING ELEMENTS 32 REAR SENSOR appears on the info display if the coolant temperature sensor of the rear cyclinder is defective. 400470-01 SENSOR ERROR appears on the info display if the coolant temperature between the coolant temperature sensors of the front and rear cylinders differs by more than the specified value. Coolant temperature 10 °C (50 °F) 400468-01 ICE appears on the info display if the external temperature falls below the specified value.
OPERATING ELEMENTS 33 ODO menu 5.17 Condition • The ignition is on. 400438-01 • ROAD mode – Press the MODE button briefly and repeatedly until ODO appears at the top left of the info display. ODO shows the total distance covered. TripDist shows the distance covered since the last reset. For example, between two refueling stops. TripDist is always running and counts up to 999.9. TripTime shows the journey time on the basis of TripDist and resumes running as soon as a speed signal is received.
OPERATING ELEMENTS 34 FUELDISTANCE menu 5.18 Condition • The ignition is on. • ROAD mode – Press the MODE button briefly and repeatedly until FUELDISTANCE appears at the top of the info display. TripFuel shows the distance covered since the fuel reserve level was reached. Info 400441-01 This is displayed only after you reach the fuel reserve level. OuterTemp shows the external temperature. The external temperature can be switched on and off in the SET‑UP menu. Press the button . Press the button .
OPERATING ELEMENTS 35 FUELRANGE menu 5.19 Condition • The ignition is on. • ROAD mode – Press the MODE button briefly and repeatedly until FUELRANGE appears at the top of the info display. TripFuel shows the distance covered since the fuel reserve level was reached. Info 400477-01 This is displayed only after you reach the fuel reserve level. MinRange shows the minimum range you can cover with the fuel reserve. MaxRange shows the maximum range you can cover with the fuel reserve.
OPERATING ELEMENTS 36 DISTANCE TO Next Service menu 5.20 Condition • The ignition is on. • The motorcycle is standing. • ROAD mode – Press the MODE button briefly and repeatedly until DISTANCE TO Next Service appears in the info display. DISTANCE TO Next Service shows the distance before the next service is necessary. 400443-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 - 5 seconds. Press the MODE button briefly.
OPERATING ELEMENTS 37 LAPSTOGO menu 5.21 Condition • The ignition is on. 400444-01 • 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 after LAPSTOGO, the stopwatch in the background is active but waiting for a speed signal. The time is not running. This function is controlled by the button "LAP".
OPERATING ELEMENTS 38 TOPSPEED menu 5.22 Condition • The ignition is on. 400445-01 • RACE mode – Press the MODE button briefly and repeatedly until TOPSPEED appears at the top left of the info display. If an R appears after TOPSPEED, the stopwatch is running in the background. If a P appears after TOPSPEED, the stopwatch is not running in the background. This function is controlled by the button "LAP". TOPSPEED shows the highest lap speed. LastLap shows the maximum speed of the last round.
OPERATING ELEMENTS 39 LAP/BESTLAP/LastLap menu 5.23 Condition • The ignition is on. 400446-01 • The motorcycle is standing. • RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/LastLap appears in the info display. LAP shows the selected lap. BESTLAP shows the number of the lap with the best lap time. LastLap shows the time of the lap behind LAP. ±Lap shows the difference to the lap before. ±Lap shows the difference to the lap after. Press the button . Press the button .
OPERATING ELEMENTS 40 LAP/BESTLAP/TopSpeed menu 5.24 Condition • The ignition is on. 400447-01 • The motorcycle is standing. • RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in the info display. LAP shows the selected lap. BESTLAP shows the lap in which the highest maximum speed was reached. TopSpeed shows maximum speed of the lap behind LAP. ±Lap shows the difference to the lap before. ±Lap shows the difference to the lap after. Press the button .
OPERATING ELEMENTS 41 Total distance menu in Race mode RACEODO 5.25 Condition • The ignition is on. 400448-01 • The motorcycle is standing. • RACE mode – Press the MODE button briefly and repeatedly until RACEODO appears at the top of the info display. RACEODO shows the total distance covered in RACE mode. RaceTrip shows the distance covered since the last reset. For example, between two refueling stops. RaceTrip is always running and counts up to 999.9.
OPERATING ELEMENTS 42 SET‑UP menu 5.26 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button for 3 - 5 seconds. On the CHANGE MODE menu, you can select between ROAD and RACE mode. You can set the clock on the SET CLOCK menu. On the SETTINGS menu, you can set the shift warning light, the lap blank time of the LAP button, the number of laps, and the reset time of the fuel reserve display.
OPERATING ELEMENTS 43 CHANGE MODE menu 5.27 Condition • The ignition is on. • The motorcycle is standing. – Press the button – Press the button or the button CHANGE MODE in the info display. and the button for 3 - 5 seconds. briefly and repeatedly until the symbol On the CHANGE MODE menu, you can select between ROAD and RACE mode. 400475-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 - 5 seconds.
OPERATING ELEMENTS 44 SET CLOCK menu 5.28 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button once until the symbol for 3 - 5 seconds. is on SET CLOCK in the info display. You can set the clock on the SET CLOCK menu. 400455-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 - 5 seconds. Press the MODE button briefly.
OPERATING ELEMENTS 45 SETTINGS menu 5.29 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol for 3 - 5 seconds. is on SETTINGS in the info display. On the SHIFT RPMS menu, you can activate the shift warning light. On the LAP BLANK TIME menu, you set the lap blank time of the LAP button. On the SET NUM LAPS menu, you set the number of laps to cover in RACE mode.
OPERATING ELEMENTS 46 SHIFT RPMS menu 5.30 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol – Press the MODE button briefly. for 3 - 5 seconds. is on SETTINGS in the info display. On the SHIFT RPMS menu, you can activate the shift warning light. 400460-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 - 5 seconds.
OPERATING ELEMENTS 47 LAP menu, LAP BLANK T button 5.31 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol is on SETTINGS in the info display. – Press the button once until the symbol is on LAP BLANK T in the info display. for 3 - 5 seconds. On the LAP BLANK T menu, you set the lap blank time of the LAP button. 400461-01 Press the button . Press the button .
OPERATING ELEMENTS 48 SET NUM LAPS menu 5.32 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol is on SETTINGS in the info display. – Press the button twice until the symbol is on SET NUM LAPS in the info display. for 3 - 5 seconds. On the SET NUM LAPS menu, you set the number of laps to cover in RACE mode. 400462-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATING ELEMENTS 49 TRIP F RESET menu 5.33 Condition • The ignition is on. 400463-01 • The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol – Press the button play. three times until the symbol for 3 - 5 seconds. is on SETTINGS in the info display. is on TRIP F RESET in the info dis- On the TRIP F RESET menu, you set the reaction time of the fuel reserve display to changes of the fuel level. Press the button . Press the button .
OPERATING ELEMENTS 50 UNITS menu 5.34 Condition • The ignition is on. 400458-01 • The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol for 3 - 5 seconds. is on UNITS in the info display. On the SET KM/MILES menu, you can set the units for measuring speed and distance. On the SET °C/°F menu, you set the unit for the temperature display. On the BACK… menu, you switch back to the SET‑UP menu.
OPERATING ELEMENTS 51 SET KM/MILES menu 5.35 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol – Press the button or the button SET KM/MILES in the info display. for 3 - 5 seconds. is on UNITS in the info display. briefly and repeatedly until the symbol is on On the SET KM/MILES menu, you can set the units for measuring speed and distance. 400464-01 Press the button . Press the button .
OPERATING ELEMENTS 52 SET °C/°F menu 5.36 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol – Press the button once until the symbol for 3 - 5 seconds. is on UNITS in the info display. is on SET °C/°F in the info display. On the SET °C/°F menu, you set the unit for the temperature display. 400465-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATING ELEMENTS 53 OPTIONS menu 5.37 Condition • The ignition is on. 400459-01 • The motorcycle is standing. – Press the button and the button – Press the button four times until the symbol for 3 - 5 seconds. is on OPTIONS in the info display. On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as accessory). On the OPTION OUTTEMP menu, you switch the external temperature display on/off. On the BACK… menu, you switch back to the SET‑UP menu.
OPERATING ELEMENTS 54 TPMS menu 5.38 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button four times until the symbol – Press the MODE button briefly. for 3 - 5 seconds. is on OPTIONS in the info display. On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as accessory). 400478-01 Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATING ELEMENTS 55 OPTION OUTERTEMP menu 5.39 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button four times until the symbol – Press the button play. once until the symbol for 3 - 5 seconds. is on OPTIONS in the info display. is on OPTIONS OUTTEMP in the info dis- On the OPTION OUTTEMP menu, you switch the external temperature display on/off. 400466-01 Press the button . Press the button .
OPERATING ELEMENTS 56 Table of functions Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 5 seconds. Press the MODE button briefly.
OPERATING ELEMENTS 57 Table of functions Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 5 seconds. Press the MODE button briefly.
OPERATING ELEMENTS 58 Table of functions . Press the button and the button for 3 - 5 seconds. Press the MODE button for 3 5 seconds. Press the MODE button briefly.
OPERATING ELEMENTS 59 Table of conditions and activability Display • The ignition is on. • The ignition is on. • The ignition is on. • The ignition is on. • The ignition is on. • ROAD mode • The motorcycle is standing. • RACE mode • The motorcycle is standing. • The motorcycle is standing.
OPERATING ELEMENTS 60 Table of conditions and activability Display • The ignition is on. • The ignition is on. • The ignition is on. • The ignition is on. • The ignition is on. • ROAD mode • The motorcycle is standing. • RACE mode • The motorcycle is standing. • The motorcycle is standing. • ROAD mode • RACE mode Menu can be activated UNITS menu • SET KM/MILES menu • SET °C/°F menu • OPTIONS menu • TPMS menu • • OPTION OUTERTEMP menu • • Displaying lap times 5.
OPERATING ELEMENTS 61 – Press the MODE button briefly and repeatedly until LAP/BESTLAP/LastLap 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 – Press the MODE button briefly. . The previous lap is displayed. 400446-01 Next display mode Displaying maximum speed 5.41 Condition The ignition is on. The motorcycle is standing.
OPERATING ELEMENTS 62 Setting ROAD or RACE mode 5.42 Condition The ignition is on. The motorcycle is standing. – Press the button – Press the button or the button CHANGE MODE in the info display. – Press the MODE button briefly. and the button for 3 - 5 seconds. briefly and repeatedly until the symbol is on The mode set is shown in the info display. 400475-01 – Select ROAD mode or RACE mode with the button – Press the MODE button briefly. – Press the button info display.
OPERATING ELEMENTS 63 – Press the button and the button – Press the button once until the symbol – Press the MODE button briefly. for 3 - 5 seconds. is on SET CLOCK in the info display. The hour is shown. – Set the hour with the button or the – Press the MODE button briefly. button . The minutes are shown. 400455-01 – Set the minutes with the button or the – Press the MODE button briefly. – Press the button info display. – Press the MODE button briefly. button .
OPERATING ELEMENTS 64 – Press the MODE button briefly. RPM1and RPM2 appear on the info display. The engine speed after RPM1 flashes. Info The engine speed can be set at intervals of 50. RPM1 is the engine speed above which the shift warning light starts to flash. – Set the engine speed with the button or the – Press the MODE button briefly. button . The engine speed after RPM2 flashes. Info RPM2 is the engine speed above which the shift warning light lights up constantly.
OPERATING ELEMENTS 65 – Press the MODE button briefly. Setting the blank time of the LAP button LAP BLANK T 5.45 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol is on SETTINGS in the info display. – Press the button once until the symbol is on LAP BLANK T in the info display. – Press the MODE button briefly. for 3 - 5 seconds. LAP BLANK T. appears on the info display. Info At delivery, LAP BLANK T.
OPERATING ELEMENTS 66 – Press the button info display. – Press the MODE button briefly. briefly and repeatedly until the symbol is on EXIT SETUP in the Setting number of laps SET NUM LAPS 5.46 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol is on SETTINGS in the info display. – Press the button twice until the symbol is on SET NUM LAPS in the info display. – Press the MODE button briefly.
OPERATING ELEMENTS 67 – Press the MODE button briefly. Setting fuel reserve display TRIPF RESET 5.47 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol – Press the button play. three times until the symbol – Press the MODE button briefly. for 3 - 5 seconds. is on SETTINGS in the info display. is on TRIP F RESET in the info dis- TRIPF RESET appears on the info display with the reaction time.
OPERATING ELEMENTS 68 Setting kilometers/miles SET KM/MILES 5.48 Info Making a country-specific setting. Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol – Press the button or the button SET KM/MILES in the info display. – Press the MODE button briefly. for 3 - 5 seconds. is on UNITS in the info display. briefly and repeatedly until the symbol is on The selected unit appears on the left of the display.
OPERATING ELEMENTS 69 Setting temperature unit SET °C/°F 5.49 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol – Press the button once until the symbol – Press the MODE button briefly. – Select the unit with the button – Press the MODE button briefly. – Press the button display. – Press the MODE button briefly. – Press the button info display. – Press the MODE button briefly.
OPERATING ELEMENTS 70 – Press the button and the button – Press the button four times until the symbol – Press the button play. once until the symbol – Press the MODE button briefly. for 3 - 5 seconds. is on OPTIONS in the info display. is on OPTIONS OUTTEMP in the info dis- You see ENABLED or DISABLED on the info display. 400466-01 – You can switch the external temperature display on/off with the button ton . – Press the MODE button briefly. – Press the button display.
OPERATING ELEMENTS 71 Opening the filler cap 5.51 700235-01 – Lift the cover of the filler cap and insert the ignition key in the lock. – Turn the ignition key clockwise until the filler cap opens. – Open the filler cap.
OPERATING ELEMENTS 72 Closing the filler cap 5.52 – Close the filler cap. Push down the filler cap slightly until the lock closes. – Remove the ignition key and close the cover. 700236-01 Supporting strap 5.53 The supporting strap is provided for the passenger to hold on to.
OPERATING ELEMENTS 73 Seat lock 5.54 The seat lock is behind the seat. It can be locked with the ignition key. 700245-01 Tool set 5.55 The tool set is in the storage compartment under the seat.
OPERATING ELEMENTS 74 Helmet lock 5.56 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 handling characteristics and vehicle operation by a fitted helmet lock or helmet. – Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out. 700337-01 Passenger footrests 5.57 The passenger footrests can be folded up and down.
OPERATING ELEMENTS 75 Shift lever 5.58 The shift lever is mounted on the left of the engine. 700239-01 The gear positions can be seen in the picture. The neutral or idle position is between the first and second gear.
OPERATING ELEMENTS 76 Foot brake pedal 5.59 The footbrake pedal is in front of the right footrest. The footbrake pedal operates the rear brake. 700237-01 Side stand 5.60 The side stand is coupled with the safety start system; see the riding instructions. Possible states • Side stand folded out – The vehicle can be leaned on the side stand. The safety start system is active. • Side stand folded in – This position is mandatory for all journeys. The safety start system is inactive.
TIPS ON PUTTING INTO OPERATION 77 TIPS ON PUTTING INTO OPERATION 6 advice on first use 6.1 Danger Danger of accidents Danger from insufficient traffic competence. – Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs. Warning Risk of injury Risk of injury by missing/inadequate protective clothing. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.
TIPS ON PUTTING INTO OPERATION 78 Info When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out exclusively by an authorized KTM-RC8 workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully. – Get to know the operating elements. – Adjust the basic position of clutch lever.
TIPS ON PUTTING INTO OPERATION – 79 Avoid full-throttle operation! Loading the vehicle 6.3 Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
TIPS ON PUTTING INTO OPERATION 80 Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution 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.
RIDING INSTRUCTIONS 81 RIDING INSTRUCTIONS 7 checks to be made before putting into operation 7.1 Info During operation, the motorcycle must be in a technically perfect condition. In the interest of riding safety, you should get into the habit of making a general check of the motorcycle before every journey. – Check the engine oil level. ( – Check the engine for oil leaks. – Check the fuel level. – Bleed fork legs. ( S. 184) S. 100) Guideline every 1,000 km (621.
RIDING INSTRUCTIONS 82 Starting 7.2 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. – Always warm up the engine at low engine speeds.
RIDING INSTRUCTIONS 83 – Press the emergency OFF switch into the position – Switch on the ignition by turning the black ignition key to the position . . When you switch on the ignition, you hear the fuel pump working for about 2 seconds. At the same time, the function test of the combination instrument is run. – Shift into neutral. – Press the electric starter button The green idling speed indicator lamp N lights up. .
RIDING INSTRUCTIONS Shifting, riding 7.4 Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. – Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
RIDING INSTRUCTIONS 85 Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles.
RIDING INSTRUCTIONS 86 Note Engine damage Engine overheating. – If the coolant temperature warning lamp lights up, stop the vehicle and switch off the engine. Let the engine cool down, and then check the coolant level in the radiator and top up if necessary. If you continue your journey with the coolant temperature warning lamp on, you can cause an engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM-RC8 workshop.
RIDING INSTRUCTIONS 87 – If the EFI warning lamp (MIL) starts to light up during the journey, stop immediately. If you shift to neutral, the EFI warning lamp (MIL) begins to flash. Info From the flash rhythm, you can deduce a two-digit number, the so-called flash code. The flash code tells you which component is affected by a fault. Braking 7.5 Warning Danger of accidents If you brake too hard, the wheels can lock. – Adapt your braking to the traffic situation and the road conditions.
RIDING INSTRUCTIONS 88 Warning Danger of accidents Delayed brake action on salted roads. – Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by braking. – When braking, first throttle back and then apply the front and rear brakes at the same time. – On wet or slippery surfaces, mainly use the rear brake. – Make sure you complete braking before going into a bend. Change down to a lower gear corresponding to your speed.
RIDING INSTRUCTIONS – 89 Do not place the vehicle where there are flammable or explosive substances. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over. – Apply the brakes. – Shift into neutral.
RIDING INSTRUCTIONS 90 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Warning Environmental hazard Improper handling of fuel is a danger to the environment.
GREASING AND SERVICE TABLE 91 GREASING AND SERVICE TABLE 8 Important service tasks to be carried out by an authorized KTM-RC8 workshop. 8.1 Engine Change the engine oil and filter, clean the oil screen. Check the valve clearance and adjust if necessary. Replace the spark plugs. x( S. 185) K150A J1A J2A • • • • • • x x • • • x Read out the status query and fault memory with KTM DIA.
GREASING AND SERVICE TABLE Attachments 92 Check bowden cables for damage, smooth operation, kink-free routing and adjustment. x Check the fluid level of the hydraulic clutch. ( K10N K75A K150A J1A J2A • • • • • • • • • • • S. 175) Check the air filter and change if necessary. Clean the air filter box. • x Drain the drainage hose of the air filter box. x Check cables for damage and kink-free routing. Check the headlight adjustment.
GREASING AND SERVICE TABLE Chassis 93 Check the steering head bearing and adjust if necessary. Check the swingarm bearing. Check deflector. x K75A K150A • • • • • • x Check the eccentric shaft adjustment. x • • • • • • • • • • • • Check the rear sprocket / engine sprocket / chain sliding guard to ensure that they are tight. • • • Check the rear sprocket / engine sprocket for wear. ( • • • • • • • • S. 128) • x • • Check the tire condition. ( S.
GREASING AND SERVICE TABLE 94 Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) 8.2 K150A Completely service fork. J2A • x Clean and grease the steering head bearing and sealing elements. Clean battery poles and treat with contact grease. Change the coolant. J1A • x Completely service shock absorber.
MAINTENANCE WORK ON CHASSIS AND ENGINE MAINTENANCE WORK ON CHASSIS AND ENGINE 9 Jacking up motorcycle front 9.1 Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle rear end. ( – Move the handlebar to the straight-ahead position. Align the work stand at the front with the adapters to the fork legs. S. 96) Work stand front (61029055300) Info Always jack up the rear of the motorcycle first.
MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up motorcycle rear 9.3 Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the rear of the work stand. Work stand adapter (61029055120) Work stand rear (61029055100) – Stand the motorcycle upright, align the work stand to the link fork and the adapters, and jack up the motorcycle. 700251-01 Taking rear of motorcycle off work stand 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 97 Fork/shock absorber 9.5 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table . You will find the table on the underside of the seat. For all damping steps, start from the maximum screwed-in position with the highest damping factor and set to the specified values.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 98 Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise the number of clicks corresponding to the fork type.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 99 Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 100 Turn the adjusting spindles clockwise until they stop. Info The adjusting spindles are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise the number of turns corresponding to the fork type. Guideline Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns full payload 3 turns Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 101 Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Perform this action on both fork legs. 700259-01 Compression damping of the shock absorber 9.10 The shock absorber can coordinate the compression damping separately in the low and high speed range (Dual Compression Control).
MAINTENANCE WORK ON CHASSIS AND ENGINE 102 Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. – Turn the adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut ! – Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE 103 Adjusting high-speed compression damping of the shock absorber 9.12 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself. Info The high-speed setting can be seen during the fast compression of the shock absorber. – Turn the adjusting screw clockwise with an open-ended spanner until it stops.
MAINTENANCE WORK ON CHASSIS AND ENGINE 104 Adjusting rebound damping of the shock absorber 9.13 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself. – Turn the adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE 105 Info The spring preload defines the initial situation of the spring process on the shock absorber. An optimally adjusted spring preload is adapted to the rider's weight and ensures a compromise between easy handling and stability. – Take the weight off the rear wheel and swingarm. Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight. – Loosen screw two turns, but do not remove.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 106 Turn the adjusting ring clockwise and tension it to the specified value. Guideline Spring preload Comfort 6 mm (0.24 in) Standard 6 mm (0.24 in) Sport 8 mm (0.31 in) full payload 8 mm (0.31 in) Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload. – Tighten screw . Guideline Remaining chassis screws 700341-11 M5 5 Nm (3.
MAINTENANCE WORK ON CHASSIS AND ENGINE 107 Steering damper 9.15 The steering damper suppresses shocks 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 manner of driving and the road conditions. For high speeds, an adjustment with high damping can be chosen in order to use the steering damping function optimally.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 108 Adjust the steering damper according to your riding style and the road conditions by turning the adjust screw clockwise towards "+".
MAINTENANCE WORK ON CHASSIS AND ENGINE 109 Vehicle level 9.17 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. The vehicle level can be adjusted at the front by means of the fork leg clamp and at the rear by the eccentric shaft. The fork legs can be clamped at three positions in the triple clamps.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting vehicle level, front 9.18 110 x Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Loosen the clamp screws of the lower and upper triple clamps and of the handlebar stub. Info Loosen the clamp screws far enough to prevent damage to the lacquer when the fork legs are moved.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 111 The fork legs can be fixed at three different positions. Guideline 700353-01 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 (standard) 5 mm (0.2 in) Info The standard adjustment is optimal for handling the vehicle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 112 – Loosen screw but do not remove it. – Turn the eccentric shaft to the desired position using the tool from the tool set. 700331-01 Guideline Standard LOW Maximum adjustment range between HIGH - LOW 180° Open end wrench SW 38 (69012021000) 700332-01 Info You can adjust the chassis height in both directions.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 113 Tighten screw . Guideline Remaining chassis screws M8 25 Nm (18.4 lbf ft) 700334-01 Footrest position 9.20 The adjustable footrest system enables an individual setting of the footrest height and an individual adjustment of the operating elements. The lower footrest position enables a more comfortable knee angle, the upper footrest position a sporting sitting position and more forward-leaning freedom for use in racing.
MAINTENANCE WORK ON CHASSIS AND ENGINE 114 – Remove screws . – Position the footrest bracket with spacers and screws. 700307-01 Guideline Standard Lower position Info The adjustable footrest bracket enables a more comfortable lower footrest position or a sporting upper footrest position. 700308-01 – Mount and tighten screws. Guideline Screw, front footrest bracket 700306-01 M8 25 Nm (18.
MAINTENANCE WORK ON CHASSIS AND ENGINE 700309-01 – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( – Adjust the footbrake pedal. ( S. 116) S.
MAINTENANCE WORK ON CHASSIS AND ENGINE 116 Adjusting shift lever stub 9.22 – Remove the screw with the shift lever stub. – Position the shift lever stub with the screw in one of the holes according to the desired lever length. Guideline Standard – Central hole Tighten screw. Guideline Screw, shift lever stub M6 10 Nm (7.4 lbf ft) 700304-01 Adjusting shift lever 9.23 Info The footrest system offers many ways of adjusting the shift lever to your riding style and requirements.
MAINTENANCE WORK ON CHASSIS AND ENGINE 117 – Remove screws and take off the shift rod. – The length of the shift rod can be adjusted by means of the screw thread. Guideline Shift rod – Loosen the counter nuts . – Adjust the shift shaft. 115… 130 mm (4.53… 5.12 in) Info Make the same adjustments on both sides.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 118 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 different positions.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 119 The position of the shift lever can be greatly varied, depending on the length of the shift rod and the drill holes selected. As seen from the footrest, there is either a high position of the shift lever or a low position of the shift lever . Info If you turn the reverse shift shaft 2 teeth on the serration of the shift shaft, you can adjust the footrest system optimally for the upper footrest position.
MAINTENANCE WORK ON CHASSIS AND ENGINE 120 Adjusting the footbrake pedal stub 9.24 – Remove the screw with the footbrake pedal stub. – Position the footbrake pedal stub with the screw in one of the holes according to the desired lever length. Guideline Standard – Central hole Tighten screw. Guideline Screw, footbrake pedal stub 700305-01 M6 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE 121 Adjusting the footbrake pedal 9.25 – Use the tool to press in the anti-rotation lock , then turn the piston rod . Info The range of adjustment is limited. – Remove the tool. The spring tension on the anti-rotation lock is released and the hex nut is locked. 700345-01 – Check the footbrake pedal setting. Info Position of the shift lever can vary considerably, depending on the setting. 700346-01 checking for chain dirt 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the chain 9.27 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Problem materials cause environmental damage.
MAINTENANCE WORK ON CHASSIS AND ENGINE 123 Checking the chain tension 9.28 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.
MAINTENANCE WORK ON CHASSIS AND ENGINE 124 Adjusting the chain tension 9.29 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.
MAINTENANCE WORK ON CHASSIS AND ENGINE 125 – Loosen nut . – Loosen nuts . – Adjust chain tension by turning the adjustment screws on the left and right. Guideline Chain tension 15… 20 mm (0.59… 0.79 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjuster are in the same position in relation to the reference marks . The rear wheel is then correctly aligned. Info The lower chain section must be taut.
MAINTENANCE WORK ON CHASSIS AND ENGINE 126 Checking rear sprocket / engine sprocket for wear 9.30 – Check the rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Change the rear sprocket / engine sprocket, chain and chain sliding guard. x Info The rear sprocket, engine sprocket, chain and chain sliding guard should always be changed together.
MAINTENANCE WORK ON CHASSIS AND ENGINE 127 Checking chain wear 9.31 – Engage neutral gear. – Pull the lower chain section with specified weight . Guideline Weight, chain wear measurement – 15 kg (33 lb.) Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance at the longest chain section » 272 mm (10.
MAINTENANCE WORK ON CHASSIS AND ENGINE 128 Checking chain sliding guard 9.32 – Check the chain sliding guard for wear at the opening. » If the rivets of the chain are no longer visible at the lower edge of the opening of the chain sliding guard: – Change the chain sliding guard. x 700351-01 Checking front brake discs 9.33 Warning Danger of accidents Reduced braking effect caused by worn brake discs. – Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 129 Checking rear brake disc 9.34 Warning Danger of accidents Reduced braking effect caused by worn brake discs. – Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop. – Check the thickness of the brake disc in several places to see if it conforms to measurement . Info Wear reduces the thickness of the brake disc in area of the brake disc. Brake discs - wear limit rear » 400480-10 4.5 mm (0.
MAINTENANCE WORK ON CHASSIS AND ENGINE 130 Checking brake fluid level of front brake 9.36 Warning Danger of accidents Failure of brake system. – If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely worn out. Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey. Warning Danger of accidents Reduced braking effect caused by old brake fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE 131 Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM-RC8 workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 132 Brake linings 9.38 The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the brake linings are entered in the homologation documents. Info Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 133 Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. x 700263-01 Checking rear brake fluid level 9.40 Warning Danger of accidents Failure of brake system. – If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely worn out.
MAINTENANCE WORK ON CHASSIS AND ENGINE 134 – Stand the vehicle upright. – Check the brake fluid level of the brake fluid reservoir. » If the fluid level reaches the MIN mark : – Top up the rear brake fluid. x( S. 134) 700264-01 Topping up rear brake fluid 9.41 x Warning Danger of accidents Failure of brake system. – If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely worn out.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE 136 Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. – Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. x 700266-01 Removing front wheel 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 137 – Loosen screws and . – Unscrew screw about 6 turns, press your hand on the screw to push the wheel spindle out of the fork stub. Remove screw . Warning Danger of accidents Reduced braking effect caused by damaged brake discs. – 700272-10 Fitting front wheel 9.44 – Always lay the wheel down in such a way that the brake discs are not damaged. Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
MAINTENANCE WORK ON CHASSIS AND ENGINE 138 – Position the brake calipers and check that the brake linings are seated correctly. – Mount and tighten screws . Guideline Screw, front brake caliper 700271-12 M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Take the front of the motorcycle off the work stand. ( – Take the rear of the motorcycle off the work stand.
MAINTENANCE WORK ON CHASSIS AND ENGINE 139 – Remove nut . Remove chain adjuster . Withdraw the wheel spindle . – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. – Pull the rear whell backwards until the brake caliper support hangs free between the brake disc and the wheel rim. 700311-01 Warning Danger of accidents Reduced braking effect caused by damaged brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE fitting the rear wheel 9.46 140 x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the footbrake until the pressure point is reached. – Check the rear hub shock absorbers. x( S.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 141 Remove bushing and bushing . Clean and grease the roll surfaces of the bushing and the shaft seal rings. Long-life grease ( S. 224) – Fit the bushings. – Clean the thread of the wheel spindle and nut. – Clean the contact areas of the brake caliper support and swingarm. – Push the brake caliper support completely to the rear. – Position the rear wheel, and position the brake caliper support between the rim and the brake disc.
MAINTENANCE WORK ON CHASSIS AND ENGINE 142 – Push the rear wheel forward as far as possible and place the chain on the rear sprocket. – Pull the rear wheel back and push in the wheel spindle. – Lay the chain adjuster on the tensioning screw. – Position the chain adjuster and place it on the tensioning screw. – Tighten nut .
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking rear hub shock absorbers 9.47 143 x Info The engine power is transmitted by the rear sprocket to the rear wheel through 5 shock absorbers. They are subject to wear during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged. – Remove the rear wheel. – Remove the rear sprocket carrier. – Check the rear hub for damage and wear. » S.
MAINTENANCE WORK ON CHASSIS AND ENGINE 144 Warning Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.
MAINTENANCE WORK ON CHASSIS AND ENGINE 145 Checking tire air pressure 9.49 Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. – Remove dust cap. – Check tire air pressure when tires are cold. Tire air pressure, Solo front 2.5 bar (36 psi) rear 2.5 bar (36 psi) Tire air pressure with passenger / full payload 700268-01 » 2.5 bar (36 psi) rear 2.
MAINTENANCE WORK ON CHASSIS AND ENGINE 146 Removing the seat 9.50 – Insert the ignition key in the seat lock and turn it anticlockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards. – Position the recesses of the seat to the lugs on the frame, lower the rear end and simultaneously push it forward. – Lock the seat by turning the ignition key in the seat lock. – Remove the ignition key from the seat lock. – Finally, check that the seat is correctly mounted.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing passenger seat 9.52 – Remove the seat. ( – Operate lever . – Take off the passenger seat toward the top. – 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. S. 146) 700246-01 Fitting the passenger seat 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 148 Mounting helmet lock on vehicle 9.54 – Remove the seat. ( – Position the steel cable from the toolset with one loop on the lug . S. 146) Steel cable (60012015000) – Guide the steel cable through the helmet opening. – Then position the free loop of the steel cable on the lug. – Position the helmet carefully on the side of the motorcycle. – Fit the seat. ( S. 146) 700336-01 Removing the battery 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery. – Remove the plus pole cover. – Disconnect the positive (plus) cable of the battery. – Remove screws . – Removing the securing bracket . – Pull the battery upwards out of the battery rack. 149 700276-10 700277-10 Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety equipment can be damaged.
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery 9.56 150 x – Position the battery in the battery rack. Info The poles of the battery must face the rear of the vehicle. – Position the bracket . – Mount and tighten screws . 700279-01 Guideline Remaining chassis screws 700277-11 M6 – Reconnect the positive (plus) cable of the battery. – Position positive terminal cover. 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Reconnect the negative (minus) cable of the battery. – Fit the seat. ( 151 S. 146) 700276-11 Recharging the battery 9.57 x Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
MAINTENANCE WORK ON CHASSIS AND ENGINE 152 Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 153 Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove the lid . Charge the battery according to the instructions on the battery casing. – After charging the battery, switch off the battery charger.
MAINTENANCE WORK ON CHASSIS AND ENGINE Info The main fuse protects all power-consuming components of the vehicle. The main fuse is under the seat. – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( – Remove protection covers . – Remove a defective main fuse with a needle nose plier. S. 146) Info A reserve fuse is located in the starter relay. – Fit a new main fuse. Fuse (58011109130) ( S.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing fuses of individual power consumers 9.59 Info The fuse box containing the fuses of individual power consumers is located under the seat. – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( – Open the fuse box cover . – Check the fuses. S. 146) 700281-01 Info A defective fuse is shown by a burned-out fuse wire .
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove defective fuse.
MAINTENANCE WORK ON CHASSIS AND ENGINE 157 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Use spare fuses with the correct rating only. Fuse (75011088010) ( S. 213) Fuse (75011088015) ( S. 213) Info If the new fuse burns out, contact an authorized KTM-RC8 workshop. Tip Replace the spare fuse in the fuse box so that it is available if needed. – Close the fuse box cover.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold up the combination instrument. Pull the lug out of the rubber holder . – Remove the rubber holder. – Release the latch . – Remove the lamp cover . – Disconnect plug-in connector . – Push off the retaining clamp on both sides, squeeze and fold to the side. – Remove headlight bulb .
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7) ( S. 213) Info Insert the headlight bulb so that the lug is positioned in the cut-out. – Position the retaining clamp. – Position the plug-in connector. – Position the lug of the lamp cover in the notch. Engage the latch . – Check lighting function.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the rubber holder . – Fold down the combination instrument. Position the lug in the rubber holder. 160 700293-11 Change the high beam bulb. 9.61 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. – Switch off all power-consuming components and switch off the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . Remove cover. – Release the latch . – Remove the lamp cover .
MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect plug-in connector . – Push off the retaining clamp on both sides, squeeze and fold to the side. – Remove headlight bulb. – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7) ( S. 213) Info Insert the headlight bulb so that the lug is positioned in the cut-out. 700299-01 – Position the retaining clamp. – Position the plug-in connector.
MAINTENANCE WORK ON CHASSIS AND ENGINE 163 – Position the lug of the lamp cover in the notch. Engage the latch. – Check lighting function. – Position cover. 400422-11 Info Check for correct positioning and freedom of movement of the brake lines. – Mount and tighten screws . Guideline Remaining chassis screws 700335-10 M6 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE 164 Changing the parking light bulb 9.62 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. 700297-01 – Switch off all power-consuming components and switch off the engine. – Remove screws . Remove cover.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Release the latch . – Remove the lamp cover . – Pull the parking light carefully out of the holder. – Remove the light bulb. – Position a new light bulb in the holder. 700298-01 Parking light (W2,1x9,5d) ( – 700300-01 S. 213) Carefully position the holder with the bulb in the holder in the headlight.
MAINTENANCE WORK ON CHASSIS AND ENGINE 166 – Position the lug of the lamp cover in the notch. Engage the latch. – Check lighting function. – Position cover. 400422-12 Info Check for correct positioning and freedom of movement of the brake lines. – Mount and tighten screws . Guideline Remaining chassis screws 700335-11 M6 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE 167 Checking headlight adjustment 9.63 0 A – On a light-colored wall behind a horizontal area, make a mark as high as the center of the low beam headlight. – Make another mark at a distance of under the first mark. Guideline B 0 Distance – 5 cm (2 in) Stand the motorcycle at distance in from of the wall and switch on the ignition and the low beam. Guideline 400420-10 Distance – 5 m (16 ft) Check the headlight adjustment.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 168 Adjust the beam distance of the headlight by turning screw . Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range. If you have a payload, you may have to correct the headlight range. 700285-01 Activating/deactivating ignition key 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 169 Switch on the ignition by turning the black ignition key to the position EFI warning lamp . (MIL) lights up, switches off, and then starts to flash. The immobilizer indicator lamp on again. lights up, switches off briefly, and switches – Switch off the ignition by turning the black ignition key to the position – Remove the black ignition key. – Insert the orange programming key in the ignition lock.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 170 Switch on the ignition by turning the orange programming key to the position EFI warning lamp . (MIL) lights up, switches off, and then starts to flash. The immobilizer indicator lamp lights up, 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 deactivated.
MAINTENANCE WORK ON CHASSIS AND ENGINE 171 – 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 ignition by turning the orange programming key to the position EFI warning lamp . (MIL) lights up, switches off, and then starts to flash.
MAINTENANCE WORK ON CHASSIS AND ENGINE 172 Cooling takes place by means of the air stream and a radiator fan , which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 400416-10 Checking the coolant level 9.67 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 173 Check the coolant level in the compensating tank. The coolant level must be between MIN and MAX. » If there is no coolant in the compensating tank: – Check the cooling system for leaks. x Info Do not operate the motorcycle! » If the coolant level in the compensating tank does not meet specifications, but the tank is not empty: – Fill the cooling system compensating tank. ( S. 173) Filling the cooling system compensating tank 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 174 Note Engine damage 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. Air in the cooling system can lead to engine failure. – Have the coolant changed by an authorized KTM-RC8 workshop. – Check the coolant level. ( – Remove the cap of the compensating tank.
MAINTENANCE WORK ON CHASSIS AND ENGINE 175 Adjusting basic position of clutch lever 9.69 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw . Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 176 Check the fluid level. The fluid level must be between the MIN and MAX markings. » If the fluid level does not meet specifications: – Correct the fluid level of the hydraulic clutch. ( S. 176) 700350-01 Correcting fluid level of hydraulic clutch 9.71 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting gas Bowden cable 9.72 177 x – Move the handlebar to the straight-ahead position. – With the diagnostics tool KTM DIA, place the control motor for the throttle valve position into the neutral position. – Loosen the counter nut . – Adjust the gas Bowden cable with the adjusting screw . Guideline Play in gas Bowden cable 700317-01 – 3… 5 mm (0.12… 0.2 in) Tighten the counter nut . Handlebar height 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 178 Adjusting handlebar height 9.74 Info The handlebar stub position must be identical on the left and the right of the vehicle. – Loosen screw . Info Loosen the screw several turns to prevent damaging the fork lacquer when moving the handlebar stub. – Remove screw . – Remove the spacer . – All cables routed under the upper triple clamp must now be routed under the handlebar stub. – Push the handlebar stub carefully up to the upper triple clamp.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 179 Tighten the screw. Guideline Screw, handlebar stub – Repeat the adjustments on the other handlebar stub. – Move the handlebar to and fro over the entire steering range. » – 20 Nm (14.8 lbf ft) If the cables restrict the freedom of movement of the steering: – 700320-01 M8 Correct the cable routing. When fitting the spacers, carry out these steps in the same way.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting rear frame position 9.76 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. Setting a higher seat position: – Remove screw with washer on the left and right side of the vehicle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 181 – Remove screw with washer on the left and right side of the vehicle. – Press the rear end up until the drill holes of the frame are level with the lower rear drill holes of the frame rear. – Fit the screw and washer on the left and right sides of the vehicle, and tighten. Guideline Screw, subframe M8 25 Nm (18.4 lbf ft) Loctite® 243™ 700327-11 – Tighten the screw on the left and right sides of the vehicle.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 182 When you screw in the rear left fixing screw, the plug-in cable binder is pushed out of the thread. To reposition the cable of the lambda probe, fix the plug-in cable binder in the remaining free drill hole. Info Check the cable routing. The cable of the lambda probe must not be taut. 700338-01 Setting a lower seat position: – Remove screw with washer on the left and right side of the vehicle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 183 – Remove screw with washer on the left and right side of the vehicle. – Press the rear end up until the drill holes of the frame are level with the upper front drill holes of the frame rear. – Fit the screw and washer on the left and right sides of the vehicle, and tighten. 700327-14 Guideline Screw, subframe M8 25 Nm (18.4 lbf ft) Loctite® 243™ 700329-01 – Tighten the screw on the left and right sides of the vehicle.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 184 When you screw in the rear left fixing screw, the plug-in cable binder is pushed out of the thread. To reposition the cable of the lambda probe, fix the plug-in cable binder in the remaining free drill hole. Info Check the cable routing. The cable of the lambda probe must not be taut. 700338-11 Checking engine oil level 9.77 Info The engine oil level must be checked at normal engine operating temperature.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 185 Remove oil dipstick . Check the engine oil level in the measurement range. Info After switching off the engine, wait one minute before checking the level. The engine oil level must be in the middle of the measurement range of the oil dipstick. » 700301-10 If the enigne oil level is outside the specified range: – – Top up the engine oil. ( S. 192) Replace the oil dipstick. Changing engine oil and filter, cleaning oil screen 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Drain the engine oil only when the engine is warm. 700302-10 – Remove screws . – Take off the left exhaust cover .
MAINTENANCE WORK ON CHASSIS AND ENGINE 187 – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove the oil drain plug with the magnet, O-rings and oil screen. – Remove the oil filter. – Completely drain the engine oil. – Thoroughly clean the magnet and oil screen of the oil drain plug. – Fit and tighten the oil drain plug with the magnet, O-rings and oil screen. x( S.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the left exhaust cover . – Mount and tighten screws . 188 Guideline Remaining chassis screws M5 5 Nm (3.7 lbf ft) 700302-10 Removing oil filter 9.80 x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. – Place a suitable container under the engine. – Remove screws . Remove the oil filter cover with the O-ring. – Pull the oil filter element out of the oil filter case. 700289-01 Circlip pliers reverse (51012011000) 700290-01 – Completely drain the engine oil.
MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting oil filter 9.81 190 x – Insert the oil filter . – Lubricate the O-ring of the oil filter cover. Fit the oil filter cover . – Mount and tighten screws. Guideline Remaining engine screws M5 6 Nm (4.4 lbf ft) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( S. 222) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S. 222) 700291-01 Filling up with engine oil 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the dipstick and top up the engine oil. Engine oil (1st quantity) – 191 3.00 l (3.17 qt.) External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( S. 222) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S. 222) Replace the oil dipstick . Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
MAINTENANCE WORK ON CHASSIS AND ENGINE 192 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. – Start the engine and check that it is oil-tight. – Check the engine oil level. ( S. 184) Topping up engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 193 Remove the dipstick and top up the engine oil. Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( S. 222) Condition External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S. 222) Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. – Replace the oil dipstick .
TROUBLESHOOTING 194 TROUBLESHOOTING 10 Faults Possible cause Action Engine doesn't crank when the electric starter button is pressed Operating error – Carry out the steps for starting. ( S. 82) Battery discharged – Recharge the battery. – Check closed-circuit current. Fuse 1, or 6 blown – Change the fuses of individual power consumers. ( S. 155) Main fuse blown – Change the main fuse. ( Ignition/steering lock or emergency OFF switch defective – Check the ignition/steering lock.
TROUBLESHOOTING 195 Faults Possible cause Action Engine cranks but doesn't start Fuel pump control defective – Check fuel pump control. Fuel quality insufficient – Add suitable fuel. Air filter very dirty – Change the air filter. Fuel filter very dirty – Chang the fuel filter. Fault in fuel injection system – Read the fault memory with KTM DIA. Too little coolant in cooling system – x Check the cooling system for leaks. x – Check the coolant level.
TROUBLESHOOTING 196 Faults Possible cause Action Brake light and horn do not work Fuse 3 blown – Change the fuses of individual power consumers. ( S. 155) Battery discharged Ignition not switched off when vehicle parked – Recharge the battery. x( Check charging voltage. x S. 151) Battery is not charged by the generator – Combination instrument shows nothing in display Fuse 1 blown – Change the fuses of individual power consumers. ( S.
IMMOBILIZER FLASH CODE 197 IMMOBILIZER FLASH CODE 11 Fault Description Possible cause Action 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short All ignition keys inactive – Activate/deactivate the ignition key. ( S. 168) 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Malfunction, antenna of immobilizer control unit – Check the antenna of the immobilizer control unit.
ENGINE CONTROL FLASH CODE 198 ENGINE CONTROL FLASH CODE 12 Fault Description Possible cause Action 02 EFI Warning lamp (MIL) flashes 2x short Malfunction in ignition pulse generator circuit – Check the ignition pulse generator. 06 EFI Warning lamp (MIL) flashes 6x short Input signal of throttle valve position generator circuit A too low – Check circuit A of throttle valve position generator.
ENGINE CONTROL FLASH CODE 199 Fault Description Possible cause Action 13 EFI Warning lamp (MIL) flashes 1x long, 3x short Input signal from intake air temperatur sensor too high – Check the intake air temperature sensor. 14 EFI Warning lamp (MIL) flashes 1x long, 4x short Input signal of pressure sensor ambient air too low – Check pressure sensor, ambient air.
ENGINE CONTROL FLASH CODE 200 Fault Description Possible cause Action 41 EFI Warning lamp (MIL) flashes 4x long, 1x short Interruption/short-circuit to ground in fuel pump control circuit – Short-circuit to plus in fuel pump control circuit – Check fuel pump control. Malfunction or short circuit to ground in lambda probe heating circuit (cylinder 1) – Check heating of lambda probe (cylinder 1).
ENGINE CONTROL FLASH CODE 201 Fault Description Possible cause Action 62 EFI Warning lamp (MIL) flashes 6x long, 2x short Malfunction in idling control system – Check idle speed control. 68 EFI Warning lamp (MIL) flashes 6x long, 8x short Connection of pressure sensor, induction manifold (cylinder 1) leaky – Check pressure sensor, induction manifold (cylinder 1).
CLEANING 202 CLEANING 13 Cleaning motorcycle 13.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
CLEANING 203 Warning Danger of accidents Reduced braking due to wet or dirty brakes. – – Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride a short distance until operating temperature is reached, and apply the brakes. Info The heat causes water to evaporate from inaccessible parts of the engine and brakes. – After the engine has cooled down, lubricate or grease all moving parts and bearings. – Clean the chain.
CONSERVATION FOR WINTER OPERATION CONSERVATION FOR WINTER OPERATION 14 Conservation for winter operation 14.1 Info If you use the motorcycle in the winter, you have to expect salt on the roads. You therefore have to take precautions against the aggressive road salt. If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt. – Clean the motorcycle.
STORAGE 205 STORAGE 15 Storage 15.1 Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.
STORAGE – 206 Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running 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. Putting into operation after storage 15.2 – Take the front of the motorcycle off the work stand.
TECHNICAL DATA - ENGINE 207 TECHNICAL DATA - ENGINE 16 Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,150 cm³ (70.18 cu in) Stroke 69 mm (2.72 in) Bore 103 mm (4.06 in) Compression ratio 12,5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - diameter Intake 42 mm (1.65 in) Exhaust 34 mm (1.34 in) Valve clearance Exhaust 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.
TECHNICAL DATA - ENGINE 208 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 390 W Spark plug NGK LKAR9BI9 Electrode gap, spark plug 0.8… 0.9 mm (0.031… 0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Cold start device Electric starter Capacity - engine oil 16.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 209 TECHNICAL DATA - ENGINE TIGHTENING TORQUES 17 Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) – Screw, gear sensor M5 3 Nm (2.2 lbf ft) Loctite® 243™ Screw, pulse generator M5 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, bearing retainer M5 6 Nm (4.4 lbf ft) Loctite® 243™ Remaining engine screws M5 6 Nm (4.4 lbf ft) – Oil jet M6x0.75 4 Nm (3 lbf ft) Loctite® 243™ Nut, cylinder head M6 10 Nm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 210 Screw, stator clamp M6 10 Nm (7.4 lbf ft) Loctite® 243™ Plug, vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) – Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™ Remaining engine screws M6 10 Nm (7.4 lbf ft) – Vacuum connection M6 5 Nm (3.7 lbf ft) Loctite® 243™ Stud, exhaust flange M8 10 Nm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 211 Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Plug, cam lever axis M10x1 15 Nm (11.1 lbf ft) – Screw, cylinder head M11x1.5 Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° Step 4 90° lubricated with engine oil Coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) – Screw, ignition rotor M12x1.5 90 Nm (66.4 lbf ft) – Spark plug M12x1.5 12 Nm (8.
TECHNICAL DATA - CHASSIS 212 TECHNICAL DATA - CHASSIS 18 Frame Lattice frame made of chromium molybdenum steel tubing, powder-coated Fork WP Suspension Up Side Down 4354 Shock absorber WP Suspension 4014 VP Suspension travel front 120 mm (4.72 in) rear 125 mm (4.
TECHNICAL DATA - CHASSIS 213 Chain 5/8 x 5/16” X‑ring Steering head angle 66.7° Wheelbase 1,435 mm (56.5 in) Seat height, unloaded Lower frame rear position 805 mm (31.69 in) Upper frame rear position 825 mm (32.48 in) Ground clearance, unloaded 110 mm (4.33 in) Weight without fuel 188 kg (414 lb.) Maximum permissible front axle load 200 kg (441 lb.) Maximum permissible rear axle load 220 kg (485 lb.) Maximum permissible total weight 380 kg (838 lb.
TECHNICAL DATA - CHASSIS Brake/tail light LED License plate lamp W2,1x9,5d 214 12 V 5W Front tire Rear tire 120/70 ZR 17 58 W TL Pirelli Dragon Supercorsa Pro 190/55 ZR 17 75 W TL Pirelli Dragon Supercorsa Pro For further information, see the Service section under: http://www.ktm.com Capacity - fuel 18.2 Fuel tank content Fuel reserve 16.5 l (4.36 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( 3.5 l (3.7 qt.) S.
TECHNICAL DATA - FORK 215 TECHNICAL DATA - FORK 19 Fork part number 05.18.7D.07 Fork WP Suspension Up Side Down 4354 Compression damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 5 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring preload - Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns full payload 3 turns Spring length with preload spacer(s) 405 mm (15.
TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER 20 Shock absorber part number 17.18.7D.07 Shock absorber WP Suspension 4014 VP Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 10 clicks Spring preload Comfort 6 mm (0.
TECHNICAL DATA - SHOCK ABSORBER Spring length 160 mm (6.3 in) Gas pressure 10 bar (145 psi) Static sag 15 mm (0.59 in) Riding sag 30 mm (1.18 in) Inbuilt length 290 mm (11.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 218 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 21 Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite® 243™ 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, chain sliding piece M5 5 Nm (3.7 lbf ft) – Screw, chain guard M5 5 Nm (3.7 lbf ft) – Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) – Screw, steering damper fixing bracket M5 5 Nm (3.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 219 Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™ Screw, spring holder on side stand bracket M8 15 Nm (11.1 lbf ft) Loctite® 243™ Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) – Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) – Screw, fork stub M8 15 Nm (11.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 220 Screw, connecting lever, shock absorber deflector M10 45 Nm (33.2 lbf ft) Loctite® 243™ Remaining chassis screws M10 45 Nm (33.2 lbf ft) – Nut, deflection lever on frame M14x1.5 100 Nm (73.8 lbf ft) – Lambda probe M18x1.5 45 Nm (33.2 lbf ft) – Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased Screw, seat lock M22x1.5 8 Nm (5.9 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.
SUBSTANCES 221 SUBSTANCES 22 Brake fluid DOT 4 / DOT 5.1 according to – DOT Specification – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Suppler Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Specification – Use only suitable coolant (even in countries with high temperatures).
SUBSTANCES 222 Engine oil (SAE 10W/50) according to – JASO T903 MA ( – SAE ( S. 226) S. 226) (SAE 10W/50) Specification – 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. fully synthetic engine oil Suppler Motorex® – Power Synt 4T Engine oil (SAE 5W/40) according to – JASO T903 MA ( – SAE ( S. 226) S.
SUBSTANCES 223 Fork oil (SAE 5) according to – SAE ( S. 226) (SAE 5) Specification – Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES 23 Chain cleaner Specification – KTM recommends Motorex® products. Suppler Motorex® – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – KTM recommends Motorex® products. Suppler Motorex® – Protect & Shine 645 High-luster polish for paint Specification – KTM recommends Motorex® products. Suppler Motorex® – Moto Polish Long-life grease Specification – KTM recommends Motorex® products.
AUXILIARY SUBSTANCES Motorcycle cleaner Specification – KTM recommends Motorex® products. Suppler Motorex® – Moto Clean 900 Onroad chain spray Specification – KTM recommends Motorex® products. Suppler Motorex® – Chain Lube 622 Strong Universal oil spray Specification – KTM recommends Motorex® products.
STANDARDS 226 STANDARDS 24 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
INDEX INDEX B Battery fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Blank time of the LAP button LAP BLANK T adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Brake disc of rear brake checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 228 E Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Footbrake pedal stub adjusting . . . . . . . . . . . . . . . . . . . . . .
INDEX 229 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 fitting to vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 High beam bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Parking light bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 ROAD mode adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Passenger footrests . . . . . . . . . . . . . . . . . .
INDEX 231 Shock absorber part number Side stand . . . . . . . . . . . Spare parts, accessories . Starting . . . . . . . . . . . . ... .... .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . 76 . .8 . 82 Steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*3211250en* 3211250en 02/2008 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.
