KTM 1190 RC8 R EU/UK 2009 Repair Manual page 5

CONTENTS
Fuel pump relay ............................................................ 88
Removing the battery ..................................................... 88
Installing the battery...................................................... 89
Recharging the battery ................................................... 90
Changing the main fuse ................................................. 91
Changing the fuses of individual power consumers............ 91
13/BRAKE SYSTEM........................................................... 93
Brake linings................................................................. 93
Checking the front brake linings...................................... 93
Changing the front brake linings ..................................... 93
Checking the front brake fluid level ................................. 95
Adding front brake fluid ................................................. 95
Adjusting the basic position of the hand brake lever.......... 96
Checking the rear brake linings ....................................... 96
Changing the rear brake linings....................................... 97
Checking the rear brake fluid level .................................. 99
Adding rear brake fluid .................................................. 99
Adjusting the foot brake pedal stub ............................... 100
Adjusting the foot brake pedal ...................................... 100
Removing the rear brake system.................................... 101
Installing the rear brake system .................................... 101
14/LIGHT SYSTEM, INSTRUMENTS ................................. 102
Immobilizer control unit ............................................... 102
Activating/deactivating ignition key ............................... 102
Activating the ICU ....................................................... 104
Combination instrument - Activation of the
BOOTLOADER mode.................................................... 105
Updating the combination instrument software............... 105
Setting ROAD or RACE mode........................................ 106
Setting the clock with SET CLOCK ................................ 106
Adjusting shift speed RPM1/2 ...................................... 106
Setting the blank time of the LAP button
LAP BLANK T ............................................................. 107
Setting the number of laps SET NUM LAPS ................... 107
Setting the fuel reserve display TRIPF RESET ................ 108
Setting the kilometers/miles SET KM/MILES .................. 108
Setting the temperature unit SET °C/°F ......................... 109
Switching the external temperature display on/off ........... 109
Resetting service display .............................................. 110
Checking the headlight setting...................................... 110
Adjust the headlight range............................................ 111
Changing the parking light bulb .................................... 111
Changing the low beam bulb......................................... 112
Changing the high beam bulb ....................................... 113
30/ENGINE..................................................................... 115
Removing the engine ................................................... 115
Preparing the engine for installation .............................. 117
Installing the engine .................................................... 117
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 120
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 121
30/DISASSEMBLING THE ENGINE................................... 122
Clamping the engine into the engine work stand ............. 122
Removing the engine bracket........................................ 122
Draining the engine oil ................................................. 122
Removing the front valve cover ..................................... 123
Removing the rear valve cover....................................... 123
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 123
Removing the starter motor .......................................... 124
Removing the oil filler tube .......................................... 124
Removing the heat exchanger ....................................... 124
Removing the rear timing chain tensioner ...................... 124
Removing the rear camshaft ......................................... 125
Removing the rear cylinder head ................................... 125
Removing the rear piston.............................................. 125
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 126
Removing the front timing chain tensioner ..................... 126
Removing the front camshafts ...................................... 126
Removing the front cylinder head.................................. 126
Removing the front piston ............................................ 127
Removing the generator cover ....................................... 127
Removing the ignition pulse generator ........................... 127
Removing the torque limiter and idler............................ 128
Removing the rotor ...................................................... 128
Removing the idler and timing chain on the left ............. 128
Removing the oil filter.................................................. 129
Removing the balancer shaft ........................................ 129
Removing the drive wheel of the balancer shaft .............. 129
Removing the gear position sensor ................................ 130
Removing the left suction pump ................................... 130
Removing the water pump wheel................................... 131
Removing the clutch cover ........................................... 131
Removing the idler and timing chain on the right............ 132
Removing the clutch facing .......................................... 132
Removing the outer clutch hub ..................................... 132
Removing the primary gear ........................................... 133
Removing the force pump ............................................ 133
Removing the shift shaft .............................................. 134
Removing the shift drum locating.................................. 134
Removing the locking lever........................................... 135
Removing the left engine case ...................................... 135
Removing the crankshaft .............................................. 135
Removing the middle suction pump .............................. 136
Removing the transmission shaft................................... 136
Removing the oil spray tube ......................................... 137
Removing the timing chain rails of the right engine case
section ....................................................................... 137
Removing the timing chain rails of the left engine case
section ....................................................................... 137
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 138
Work on the right section of the engine case .................. 138
Removing the main bearing of the right engine case
section ....................................................................... 139
Selecting the main bearing shells.................................. 140
Installing the right main bearing ................................... 140
Work on the left section of the engine case .................... 141
Removing the left main bearing .................................... 143
Installing the left main bearing ..................................... 143
Changing the conrod bearing ........................................ 144
Work on the clutch cover .............................................. 145
Changing the step bearing of the crankshaft................... 146
Checking the radial clearance of the bottom connecting
rod bearing ................................................................. 147
Checking/measuring the cylinder................................... 147
Checking/measuring the piston ..................................... 148
Checking the piston ring end gap .................................. 149
Checking the piston/cylinder mounting clearance............ 149
Work on the cylinder head ............................................ 149
Checking the cylinder head .......................................... 152
Work on the right idler ................................................. 153
Checking the timing assembly ...................................... 154
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