Table Of Contents - KTM 1190 RC8 R EU/UK 2009 Repair Manual

CONTENTS
CONTENTS
MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
LOCATION OF SERIAL NUMBERS ........................................ 8
Vehicle identification number/type label ............................ 8
Key number .................................................................... 8
Engine number................................................................ 8
Fork part number............................................................. 8
Shock absorber part number............................................. 8
Steering damper part number ........................................... 9
MOTORCYCLE................................................................... 10
Jacking up motorcycle front............................................ 10
Taking front of motorcycle off work stand......................... 10
Jacking up the motorcycle in the middle (screw-in type).... 10
Removing the motorcycle from the work stand (screw-in
type) ............................................................................ 11
Jacking up the motorcycle in the middle (insertable
type) ............................................................................ 12
Removing the motorcycle from the work stand (insertable
type) ............................................................................ 12
Jacking up motorcycle at the rear.................................... 13
Taking the rear from the workstand ................................. 13
Starting ........................................................................ 13
01/FORK, TRIPLE CLAMP.................................................. 15
Adjusting the compression damping of the fork ................ 15
Adjusting the rebound damping of the fork....................... 15
Adjusting the spring preload of the fork ........................... 16
Bleeding fork legs.......................................................... 16
Vehicle level ................................................................. 17
Adjusting front vehicle level............................................ 17
Removing the fork ......................................................... 18
Installing the fork .......................................................... 19
performing a fork service ................................................ 21
Disassembling the fork legs ............................................ 21
Disassembling the outer tubes ........................................ 24
Checking the fork legs.................................................... 25
changing the lower DU bush ........................................... 26
Assembling the outer tubes ............................................ 27
Assembling the fork legs ................................................ 27
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 32
Adjusting basic position of clutch lever............................ 32
Adjusting the steering damper ........................................ 32
Adjusting the handlebar height ....................................... 32
Adjusting the play in the throttle cable ............................ 33
Throttle grip.................................................................. 34
Changing the throttle grip............................................... 34
Adjusting the throttle cable at the throttle valve................ 37
03/FRAME........................................................................ 40
Side stand switch .......................................................... 40
Footrest position............................................................ 40
Adjusting footrest position.............................................. 40
Rear frame position ....................................................... 41
Adjusting the rear frame position .................................... 41
04/SHOCK ABSORBER, SWINGARM................................... 44
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the rebound damping of the shock absorber....... 45
Adjusting the spring preload of the shock absorber ........... 45
Adjusting the vehicle level at the rear .............................. 46
Removing the shock absorber ......................................... 46
Installing the shock absorber .......................................... 47
Servicing the shock absorber .......................................... 48
Removing the spring ...................................................... 48
Disassembling the damper ............................................. 49
Disassembling the piston rod .......................................... 50
Checking the damper ..................................................... 51
Assembling the piston rod .............................................. 52
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 58
Installing the spring....................................................... 59
Removing the heim joint ................................................ 59
Installing the heim joint ................................................. 60
05/EXHAUST .................................................................... 62
Lambda sensor.............................................................. 62
Lambda sensor heater .................................................... 62
Removing the exhaust cover completely ........................... 63
Installing the exhaust cover completely............................ 63
Removing the exhaust system ......................................... 63
Installing the exhaust system.......................................... 65
06/AIR FILTER.................................................................. 67
Removing the air filter ................................................... 67
Installing the air filter .................................................... 67
Removing the filter box bottom ....................................... 67
Installing the filter box bottom........................................ 68
07/FUEL TANK, SEAT, TRIM.............................................. 70
Removing the seat ......................................................... 70
Fitting the seat.............................................................. 70
Removing the passenger seat.......................................... 70
Mounting the passenger seat .......................................... 70
Dismounting the fuel tank .............................................. 70
Installing the fuel tank ................................................... 71
Removing the fuel tank guard ......................................... 72
Installing the fuel tank guard.......................................... 73
Checking the fuel pressure ............................................. 73
Checking the fuel pressure during the actuator test........... 74
08/MASK, FENDER, DECAL ............................................... 75
Removing the side covers ............................................... 75
Installing the side covers................................................ 75
Removing the inside cover.............................................. 75
Installing the inside cover .............................................. 76
09/FRONT WHEEL ............................................................ 77
Removing the front wheel ............................................... 77
Installing the front wheel................................................ 77
Checking the tire condition............................................. 78
Checking the tire pressure .............................................. 79
Checking the front brake discs........................................ 80
10/REAR WHEEL .............................................................. 81
Removing the rear wheel ................................................ 81
Installing the rear wheel ................................................. 81
Installing the rear wheel - when installing the engine ........ 82
Checking the rear brake disc........................................... 83
Checking for chain dirt................................................... 83
Cleaning the chain......................................................... 84
Checking the chain tension ............................................ 84
Adjusting the chain tension ............................................ 85
Checking rear sprocket / engine sprocket for wear ............. 85
Checking chain wear ...................................................... 86
Checking chain sliding guard .......................................... 86
Checking rear hub cush drive.......................................... 86
11/WIRING HARNESS, BATTERY ....................................... 88
Electric starter lock control unit ...................................... 88
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