Page 1 OWNER'S MANUAL 2009 1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR 1190 RC8 R JP ART. NO. 3211375en...
Page 3 DEAR KTM CUSTOMER We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcy- DEAR KTM CUSTOMER cle that will give you a great deal of pleasure during your ownership if you service and maintained it accordingly.
Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
Page 5: Table Of Contents
CONTENTS Notes/warnings on the combination instrument....30 CONTENTS MEANS OF REPRESENTATION ..........7 Odometer menu ODO/Trip 1 ..........33 IMPORTANT NOTES ............... 8 Odometer menu ODO/Trip 2 ..........34 VIEW OF VEHICLE..............12 FUELDISTANCE menu ............35 View of vehicle, front left side..........12 FUELRANGE menu............
Page 6 Setting the fuel reserve display TRIPF RESET ..... 68 Important service tasks to be carried out by an authorized Setting the kilometers/miles SET KM/MILES ....... 69 KTM-RC8 workshop. (as additional job) ......95 Setting the temperature unit SET °C/°F ......70 MAINTENANCE WORK ON FRAME AND ENGINE....96 Switching the external temperature display on/off ....
Page 7 CONTENTS Adjusting shift lever stub..........116 Fitting the seat............... 148 Adjusting shift lever............116 Removing the passenger seat........... 149 Adjusting the footbrake pedal stub ........120 Mounting the passenger seat ........... 149 Adjusting the footbrake pedal .......... 121 Mounting the helmet lock on the vehicle......150 Checking for chain dirt............
Page 8 CONTENTS INDEX ................234 Draining engine oil, cleaning oil screens ...... 188 Removing the oil filter ..........191 Installing the oil filter ..........193 Filling up with engine oil ..........193 Adding engine oil ............195 TROUBLESHOOTING............197 IMMOBILIZER BLINK CODE..........200 ENGINE CONTROL BLINK CODE .........
Page 9: Means Of Representation
All jobs marked with this symbol require specialist knowledge and technical understanding. In the interests of your own safety, have these jobs done in an authorized KTM-RC8 workshop! There, your motorcycle will be handled opti- mally by specially trained experts with the necessary special tools.
Page 10: Important Notes
IMPORTANT NOTES 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.
Page 11 IMPORTANT NOTES Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be glad to advise you. You will find the current KTM PowerParts for your vehicle on the KTM website.
Page 12 IMPORTANT NOTES Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and con- flicts.
Page 13 IMPORTANT NOTES Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Page 14: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left side 100652-10...
Page 15 VIEW OF VEHICLE Clutch lever Light switch, headlight flasher switch, indicator switch, horn button Filler cap Seat Seat lock Oil dipstick Side stand Shift lever Passenger footrests...
Page 16: View Of Vehicle, Rear Right Side
VIEW OF VEHICLE View of vehicle, rear right side 100653-10...
Page 17 VIEW OF VEHICLE Passenger seat Supporting strap Rear mirror Combination instrument Emergency OFF switch, electric starter button Hand brake lever Chassis number, type label Rear brake caliper Foot brake pedal Engine number Brake calipers, front...
Page 18: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Vehicle identification number/type label The vehicle identification number is stamped on the frame behind the steering head on  the right. The type label is on the frame above the vehicle identification number.  100654-10 Key number The key number Code number can be found on the KEYCODECARD.
Page 19: Engine Number
LOCATION OF SERIAL NUMBERS Engine number The engine number is stamped on the right side of the engine.  100655-10 Fork part number The fork part number is stamped on the inner side of the fork stub.  100656-10...
Page 20: Shock Absorber Part Number
LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber  above the adjusting ring towards the rear. 100657-10 Steering damper part number The steering damper part number is stamped on the top of the steering damper.
Page 21: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulic and self-adjusting. 100659-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar.  The hand brake lever operates the front brake.
Page 22: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – The light switch is in the lower position. In this position, the low beam and tail light are switched on. High beam on –...
Page 23: Turn Signal Switch
CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar.  Possible states Turn signal off Left turn signal on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use. Right turn signal on –...
Page 24: Ignition/Steering Lock
CONTROLS Ignition/steering lock The ignition/steering lock is located in front of the upper triple clamp.  Info The ignition may only be switched on using a black ignition key. Use the orange programming key to activate and deactivate the black ignition key. Possible states Ignition off OFF –...
Page 25: Electric Starter Button
The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM RC8 workshop, but they must be activated before use.
Page 26: Combination Instrument - Overview
CONTROLS Combination instrument - overview 5.11 Display ( p. 27) Function buttons Indicator lamps ( p. 29) Info display ( p. 28) 400580-10...
Page 27: Combination Instrument - Function Buttons On Handlebar
CONTROLS Combination instrument - function buttons on handlebar 5.12 The MODE button is fitted on the handlebar, front left.  The LAP button is fitted on the handlebar, rear left.  MODE button Changes to the next item on the info display in ROAD mode and in RACE mode. LAP button Changes to the next item in the info display in ROAD mode.
Page 28: Combination Instrument - Activation And Test
The speed display counts from 0 to 300 and back. The remaining display segments outside the info display light up briefly. The KTM logo appears in the info display. In ROAD mode, the info display switches to ODO, Trip 1, Time 1, Avs 1 mode.
Page 29: Display
CONTROLS Display 5.14 The tachometer displays the engine speed in revolutions per minute (RPM).  The red marking marks the over-rev (excessive speed) range of the engine.  The speed is displayed in kilometers per hour km/h or in miles per hour Mph. ...
Page 30: Info Display
CONTROLS Info display 5.15 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 tracks. It allows riders to time laps themselves. If the general warning lamp lights up, the corresponding message is shown periodically in the info display.
Page 31: Indicator Lamps
CONTROLS Indicator lamps 5.16 Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The oil indicator lamp lights up red – The oil pressure is too low. The shift warning lights up/flashes red – The set shift speed has been reached.
Page 32: Notes/Warnings On The Combination Instrument
CONTROLS Notes/warnings on the combination instrument 5.17 LOW FUEL appears on the info display if the minimum range falls below the specified value. Distance 20 km (12.4 mi) 400476-01 LOW BATTERY appears on the info display if the battery voltage falls below the specified value.
Page 33 CONTROLS 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.
Page 34 CONTROLS REAR SENSOR appears on the info display if the rear cylinder coolant temperature sensor is faulty. 400470-01 SENSOR ERROR appears on the info display if the discrepancy between the front and rear cylinder coolant temperature sensor values differs by more than the specified value. Coolant temperature 10 °C (50 °F) 400468-01...
Page 35: Odometer Menu Odo/Trip 1
CONTROLS Odometer menu ODO/Trip 1 5.18 Condition • The ignition is on. • 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. Trip 1 shows the distance covered since the last reset.
Page 36: Odometer Menu Odo/Trip 2
CONTROLS Odometer menu ODO/Trip 2 5.19 Condition • The ignition is on. • 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. Trip 2 shows the distance covered since the last reset.
Page 37: Fueldistance Menu
CONTROLS FUELDISTANCE menu 5.20 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 This is displayed only after you reach the fuel reserve level.
Page 38: Fuelrange Menu
CONTROLS FUELRANGE menu 5.21 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 This is displayed only after you reach the fuel reserve level.
Page 39: Distance To Next Service Menu
CONTROLS DISTANCE TO Next Service menu 5.22 Condition • The ignition is on. • The motorcycle is upright. • 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. Press the button No function 400443-01...
Page 40: Lapstogo Menu
CONTROLS LAPSTOGO menu 5.23 Condition • The ignition is on. • 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.
Page 41: Topspeed Menu
CONTROLS TOPSPEED menu 5.24 Condition • The ignition is on. • 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.
Page 42: Lap/Bestlap/Lastlap Menu
CONTROLS LAP/BESTLAP/LastLap menu 5.25 Condition • The ignition is on. • The motorcycle is upright. 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.
Page 43: Lap/Bestlap/Topspeed Menu
CONTROLS LAP/BESTLAP/TopSpeed menu 5.26 Condition • The ignition is on. • The motorcycle is upright. 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.
Page 44: Total Distance Menu In Race Mode Raceodo
CONTROLS Total distance menu in Race mode RACEODO 5.27 Condition • The ignition is on. • The motorcycle is upright. • 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.
Page 45: Set-Up Menu
CONTROLS SET‑UP menu 5.28 Condition • The ignition is on. • The motorcycle is upright. – 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.
Page 46: Change Mode Menu
CONTROLS CHANGE MODE menu 5.29 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the MODE button briefly. On the CHANGE MODE menu, you can select between ROAD and RACE mode. Press the button Changes the menu Press the button...
Page 47: Set Clock Menu
CONTROLS SET CLOCK menu 5.30 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button once until the symbol shows SET CLOCK in the info display. –...
Page 48: Settings Menu
On the TRIP F RESET menu, you can set the reaction time of the fuel reserve display to changes of the fuel level. Only a KTM-RC8 workshop can make changes on the S.LEARN TPMS menu. On the BACK… menu, you can switch back to the SET‑UP menu.
Page 49: Shift Rpms Menu
CONTROLS SHIFT RPMS menu 5.32 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 50: Lap Menu, Lap Blank T Button
CONTROLS LAP menu, LAP BLANK T button 5.33 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 51: Set Num Laps Menu
CONTROLS SET NUM LAPS menu 5.34 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 52: Trip F Reset Menu
CONTROLS TRIP F RESET menu 5.35 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 53: Units Menu
CONTROLS UNITS menu 5.36 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
Page 54: Set Km/Miles Menu
CONTROLS SET KM/MILES menu 5.37 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
Page 55: Set °C/°F Menu
CONTROLS SET °C/°F menu 5.38 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
Page 56: Options Menu
CONTROLS OPTIONS menu 5.39 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
Page 57: Tpms Menu
CONTROLS TPMS menu 5.40 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
Page 58: Outertemp Menu
CONTROLS OUTERTEMP menu 5.41 Condition • The ignition is on. • The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
Page 59 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE button and the button ton for 3 - 5 sec- briefly. 3 - 5 seconds. onds. Odometer menu No function No function The display The display of...
Page 60 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE button and the button ton for 3 - 5 sec- briefly. 3 - 5 seconds. onds. LAP/BESTLAP/Top- The next lap is dis- The previous lap is The display All values in...
Page 61 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE button and the button ton for 3 - 5 sec- briefly. 3 - 5 seconds. onds. SET NUM LAPS Increases the value Decreases the value No function Open and exit...
Page 62 CONTROLS Table of conditions and activability Display Menu can be • The igni- • The igni- • The igni- • The igni- • The igni- activated tion is on. tion is on. tion is on. tion is on. tion is on. •...
Page 63: Displaying Lap Times
CONTROLS Table of conditions and activability Display Menu can be • The igni- • The igni- • The igni- • The igni- • The igni- activated tion is on. tion is on. tion is on. tion is on. tion is on. •...
Page 64: Displaying Maximum Speed
CONTROLS – 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 The previous lap is displayed. –...
Page 65: Setting Road Or Race Mode
CONTROLS Setting ROAD or RACE mode 5.44 Condition The ignition is on. The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the MODE button briefly. The mode set is shown in the info display. –...
Page 66: Adjusting Shift Speed Rpm1/2
CONTROLS – Press the MODE button briefly. The settings are stored and the display changes to the SET‑UP menu. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. – Press the MODE button briefly. Adjusting shift speed RPM1/2 5.46 Condition...
Page 67: Setting The Blank Time Of The Lap Button Lap Blank T
CONTROLS Info RPM2 is the engine speed above which the shift warning light lights up con- stantly. If RPM1 = RPM2, the shift warning light lights up constantly when you reach the engine speed set. – Set the engine speed with the button or the button –...
Page 68 CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. – Press the MODE button briefly. – Press the button once until the symbol shows LAP BLANK T in the info display.
Page 69: Setting The Number Of Laps Set Num Laps
CONTROLS Setting the number of laps SET NUM LAPS 5.48 Condition The ignition is on. The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 70: Setting The Fuel Reserve Display Tripf Reset
CONTROLS Setting the fuel reserve display TRIPF RESET 5.49 Condition The ignition is on. The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. –...
Page 71: Setting The Kilometers/Miles Set Km/Miles
CONTROLS Setting the kilometers/miles SET KM/MILES 5.50 Info Making a country-specific setting. Condition The ignition is on. The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display.
Page 72: Setting The Temperature Unit Set °C/°F
CONTROLS Setting the temperature unit SET °C/°F 5.51 Condition The ignition is on. The motorcycle is upright. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
Page 73 CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. – Press the MODE button briefly. – Press the button once until the symbol shows OPTION OUTTEMP in the info display.
Page 74: Opening The Filler Cap
CONTROLS Opening the filler cap 5.53 – 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. 100666-10...
Page 75: Closing The Filler Cap
CONTROLS Closing the filler cap 5.54 Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – When closing the filler cap, ensure that it is closed correctly. Change cloth- ing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.
Page 76: Seat Lock
CONTROLS Seat lock 5.56 The seat lock is behind the seat.  It can be locked with the ignition key. 100669-10 Tool set 5.57 The tool set is in the storage compartment under the seat.  100670-10...
Page 77: Helmet Lock
CONTROLS Helmet lock 5.58 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen. Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.
Page 78: Shift Lever
CONTROLS Shift lever 5.60 The shift lever is mounted on the left of the engine.  100673-10 The gear positions can be seen in the picture. The neutral or idle position is between the first and second gear.  100674-10...
Page 79: Foot Brake Pedal
CONTROLS Foot brake pedal 5.61 The foot brake pedal is in front of the right footrest.  The foot brake pedal operates the rear brake. 100675-10 Side stand 5.62 The side stand is coupled with the safety start system; see the riding instructions. ...
Page 80: General Tips And Hints On Putting Into Operation
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling 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. –...
Page 81: Running The Engine In
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.
Page 82: Loading The Vehicle
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Loading the vehicle 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.
Page 83 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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 distribu- tion between the front and rear wheels.
Page 84: Riding Instructions
RIDING INSTRUCTIONS Checks to be made before putting into operation 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. –...
Page 85: Starting
RIDING INSTRUCTIONS – Sit on the motorcycle and check the setting of the rear mirror. Starting 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 without an effective exhaust extraction system.
Page 86: Starting Up
RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch off the ignition by turning the black programming key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds.
Page 87: Shifting, Riding
RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents 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 shift down at high engine speed, the rear wheel can lock up. –...
Page 88 RIDING INSTRUCTIONS 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. –...
Page 89 Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM-RC8 workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
Page 90: Braking
Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking effect caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey. Warning Danger of accidents Brake system failure. –...
Page 91: Stopping, Parking
RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. –...
Page 92: Refueling
RIDING INSTRUCTIONS – Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components due to excessive load. –...
Page 93 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with 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 doc- tor immediately.
Page 94: Service Schedule
SERVICE SCHEDULE Important service tasks to be carried out by an authorized KTM-RC8 workshop. K10N K75A K150A engine • • • • • Change the engine oil and filter, clean the oil screen. p. 187) • Check the valve clearance.
Page 95 SERVICE SCHEDULE K10N K75A K150A Attachments Check the exhaust system for leaks and correct fitting and check that • • • the exhaust brackets are tight. Check the control cables for damage, smooth operation, kink-free rout- • • • • •...
Page 96 SERVICE SCHEDULE K10N K75A K150A Chassis Check the operation of the forks and the rear shock absorber, also • • • • • check for leaks. Bleed fork legs. ( p. 101) • • • • • • • • Check the steering head bearings and adjust if necessary.
Page 97: Important Service Tasks To Be Carried Out By An Authorized Ktm-Rc8 Workshop. (As Additional Job)
SERVICE SCHEDULE Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) K150N K150A K300A • • • • Perform a fork service. • • Perform a shock absorber service. • • • • Clean and grease the steering head bearing and sealing elements.
Page 98: Maintenance Work On Frame And Engine
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle front Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle rear end. ( p.
Page 99: Jacking Up Motorcycle Rear
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle rear Note Danger of damage The parked vehicle can roll away or fall 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) –...
Page 100: Fork/Shock Absorber
MAINTENANCE WORK ON FRAME AND ENGINE Fork/shock absorber 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 .
Page 101: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON FRAME AND ENGINE – 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 by the number of clicks corresponding to the fork type. Guideline Compression damping 100682-10...
Page 102: Adjusting The Spring Preload Of The Fork
MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screws clockwise to the stop.  Info The adjusting screws are located at the top end of the fork legs. Adjust both fork legs to the same setting. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort...
Page 103: Bleeding Fork Legs
MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screws clockwise to the stop.  Info The adjustment screws are located at the top end of the fork legs. Adjust both fork legs to the same setting. – Turn back counterclockwise by the number of turns according to the fork type. Guideline Spring preload - Preload Adjuster Comfort...
Page 104: Compression Damping Of The Shock Absorber
Adjusting the low-speed compression damping of the shock absorber 9.11 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.)
Page 105: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Adjusting the high-speed compression damping of the shock absorber 9.12 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.)
Page 106: Adjusting The Rebound Damping Of The Shock Absorber
Adjusting the rebound damping of the shock absorber 9.13 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.)
Page 107: Adjusting The Spring Preload Of The Shock Absorber
MAINTENANCE WORK ON FRAME AND ENGINE – Turn adjusting screw clockwise up to the last perceptible click.  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks...
Page 108 MAINTENANCE WORK ON FRAME AND ENGINE – 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.
Page 109: Steering Damper
MAINTENANCE WORK ON FRAME AND ENGINE – Tighten screw  Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) 100689-11 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 riding style and the road conditions.
Page 110 MAINTENANCE WORK ON FRAME AND ENGINE – Turn the adjusting screw counterclockwise towards "–" as far as the last perceptible  click. – Adjust the steering damper according to your riding style and the road conditions by turning the adjust screw clockwise towards "+". Guideline Steering damper adjustment range 1…...
Page 111: Vehicle Level
MAINTENANCE WORK ON FRAME AND ENGINE Vehicle level 9.17 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behav- ior.
Page 112: Adjusting Front Vehicle Level
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting front vehicle level 9.18 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...
Page 113 MAINTENANCE WORK ON FRAME AND ENGINE Info The standard adjustment is the setting that provides the best vehicle handling. When the fork is compressed, the suspension setting changes, causing the vehi- cle to become more stable but also more difficult to handle. –...
Page 114: Adjusting The Vehicle Level At The Rear
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the vehicle level at the rear 9.19 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...
Page 115: Footrest Position
MAINTENANCE WORK ON FRAME AND ENGINE – Tighten screw  Guideline Screw, clamp, eccentric shaft of deflec- 18 Nm (13.3 lbf ft) 100698-10 Footrest position 9.20 The adjustable footrest system enables an individual setting of the footrest height and an individual adjustment of the operating elements.
Page 116 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  100713-10 – Position the footrest bracket with spacers and screws.  Guideline Standard Lower position Info The adjustable footrest bracket enables a more comfortable lower footrest posi- tion or a sporting upper footrest position. 100700-10 –...
Page 117 MAINTENANCE WORK ON FRAME AND ENGINE – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( p. 116) – Adjust the footbrake pedal. ( p. 121) 100702-01...
Page 118: Adjusting Shift Lever Stub
MAINTENANCE WORK ON FRAME AND ENGINE 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...
Page 119 MAINTENANCE WORK ON FRAME AND ENGINE – 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 115… 130 mm (4.53… 5.12 in) –...
Page 120 MAINTENANCE WORK ON FRAME AND ENGINE – The shift rod can be mounted both on the shift lever variably at an upper or lower posi- tion, and on the reverse gear change of the shift shaft in two different positions. Guideline Standard Shift lever: lower drill hole,...
Page 121 MAINTENANCE WORK ON FRAME AND ENGINE – 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 ...
Page 122: Adjusting The Footbrake Pedal Stub
MAINTENANCE WORK ON FRAME AND ENGINE 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.
Page 123: Adjusting The Footbrake Pedal
MAINTENANCE WORK ON FRAME AND ENGINE 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.
Page 124: Checking For Chain Dirt
MAINTENANCE WORK ON FRAME AND ENGINE Checking for chain dirt 9.26 – Check the chain for loose dirt. » If the chain is very dirty: – Clean the chain. ( p. 122) 400678-01 Cleaning the chain 9.27 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...
Page 125: Checking The Chain Tension
MAINTENANCE WORK ON FRAME AND ENGINE Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.
Page 126: Adjusting The Chain Tension
MAINTENANCE WORK ON FRAME AND ENGINE – Lean the motorcycle on the side stand. – Shift into neutral. – In the area in front of where the chain passes through the link fork, push the chain upward and measure chain tension ...
Page 127 MAINTENANCE WORK ON FRAME AND ENGINE – 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 ...
Page 128: Checking Rear Sprocket / Engine Sprocket For Wear
MAINTENANCE WORK ON FRAME AND ENGINE 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. Info The rear sprocket, engine sprocket, chain and chain sliding guard should always be changed together.
Page 129: Checking Chain Wear
MAINTENANCE WORK ON FRAME AND ENGINE Checking chain wear 9.31 – Shift the transmission to neutral. – Pull the lower chain section with specified weight  Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. ...
Page 130: Checking Chain Sliding Guard
Change the chain sliding guard. 100710-10 Checking the front brake discs 9.33 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 131: Checking The Rear Brake Disc
– Change the brake discs. Checking the rear brake disc 9.34 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 132: Adjusting The Basic Position Of The Handbrake Lever
MAINTENANCE WORK ON FRAME AND ENGINE – Check the thickness of the brake disc in several places to see if it conforms to measure- ment  Info Wear reduces the thickness of the brake disc in area of the brake disc. ...
Page 133: Checking The Front Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Page 134 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Page 135: Brake Linings
Info Brake linings available in accessory shops have often not been tested by and thus not approved for use on KTM vehicles. The struc- ture and friction coefficient of the brake linings, and therefore the brake power, may vary considerably from original KTM brake linings.
Page 136: Checking Rear Brake Fluid Level
(Your authorized KTM RC8 workshop will be pleased to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 137: Adding Rear Brake Fluid
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 138: Checking The Rear Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. 100717-10 Checking the rear brake linings 9.42 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 139: Removing The Front Wheel
MAINTENANCE WORK ON FRAME AND ENGINE Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable.
Page 140 MAINTENANCE WORK ON FRAME AND ENGINE – Loosen screws   – Unscrew screw about 6 turns, press your hand on the screw to push the wheel spin-  dle out of the fork stub. Remove screw  Warning Danger of accidents Reduced braking effect caused by damaged brake discs. –...
Page 141: Installing The Front Wheel
MAINTENANCE WORK ON FRAME AND ENGINE Installing the front wheel 9.44 – Clean and grease the shaft seal rings and mating surfaces of the spacers.   Long-life grease ( p. 231) 100781-10 – Insert the wide spacer on the left-hand side (when looking in the direction of travel).
Page 142 MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. –...
Page 143: Removing The Rear Wheel
MAINTENANCE WORK ON FRAME AND ENGINE – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten bolts  Guideline Fork end pinch bolts 15 Nm (11.1 lbf ft) 100782-10 Removing the rear wheel 9.45 –...
Page 144: Installing The Rear Wheel
MAINTENANCE WORK ON FRAME AND ENGINE – Push the rear wheel as far forward as possible and then remove the chain from the rear sprocket. Warning Danger of accidents Reduced braking effect caused by damaged brake discs. – Always lay the wheel down in such a way that the brake discs are not dam- aged.
Page 145 MAINTENANCE WORK ON FRAME AND ENGINE – Remove spacer . Clean and grease the mating surfaces of the spacers and the shaft  seal rings. Long-life grease ( p. 231) – Install the spacer. – Clean the thread of the axle and nut. –...
Page 146: Checking Rear Hub Cush Drive
MAINTENANCE WORK ON FRAME AND ENGINE – Place the chain adjuster on the tensioning screw.  – Position the chain adjuster and place it on the tensioning screw.  – Tighten nut  Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks ...
Page 147: Checking The Tire Condition
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling 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.
Page 148 MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.
Page 149: Checking The Tire Pressure
DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years.
Page 150: Removing The Seat
MAINTENANCE WORK ON FRAME AND ENGINE – Mount the dust cap. Info The rubber seal in the dust cap prevents air leaking out of the tire if the valve is defective. Removing the seat 9.50 – Insert the ignition key in the seat lock and turn it clockwise.
Page 151: Removing The Passenger Seat
MAINTENANCE WORK ON FRAME AND ENGINE Removing the passenger seat 9.52 – Remove the seat. ( p. 148) – Activate the release lever  – Take off the passenger seat toward the top.  100731-10 Mounting the passenger seat 9.53 Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.
Page 152: Mounting The Helmet Lock On The Vehicle
MAINTENANCE WORK ON FRAME AND ENGINE Mounting the helmet lock on the vehicle 9.54 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle. – Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before start- ing out.
Page 153 MAINTENANCE WORK ON FRAME AND ENGINE Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged. – Never operate the vehicle with a discharged battery or without a battery. –...
Page 154: Installing The Battery
MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Removing the securing bracket  – Pull battery up and out of the battery rack. 100736-10 Installing the battery 9.56 – Position the battery in the battery rack. Info The poles of the battery must face the rear of the vehicle.
Page 155 MAINTENANCE WORK ON FRAME AND ENGINE – Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Reconnect the positive (plus) cable of the battery.  – Position positive terminal cover. 100738-10 – Reconnect the negative (minus) cable of the battery.
Page 156: Recharging The Battery
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 157 MAINTENANCE WORK ON FRAME AND ENGINE Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
Page 158: Changing The Main Fuse
MAINTENANCE WORK ON FRAME AND ENGINE – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove lid ...
Page 159 MAINTENANCE WORK ON FRAME AND ENGINE Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. – Switch off all power consumers and the engine. – Remove the seat. ( p. 148) –...
Page 160: Changing The Fuses Of Individual Power Consumers
MAINTENANCE WORK ON FRAME AND ENGINE Changing the fuses of individual power consumers 9.59 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. Info The fuse box containing the fuses of individual power consumers is located under the seat.
Page 161 MAINTENANCE WORK ON FRAME AND ENGINE – Check the fuses. Info A defective fuse can be identified by the burned-out fuse wire  – Remove the faulty fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system (optional) 100741-10 Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp...
Page 162: Changing The Low Beam Bulb
MAINTENANCE WORK ON FRAME AND ENGINE – Close the fuse box cover. – Fit the seat. ( p. 148) Changing the low beam bulb 9.60 Note Damage to reflector Reduced luminance. – Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean the bulb and keep it free of grease before mounting.
Page 163 MAINTENANCE WORK ON FRAME AND ENGINE – Release the latch  – Remove the lamp cover  100743-10 – Disconnect plug-in connector  – Push off the retaining clamp on both sides, squeeze and fold to the side.  – Remove headlight bulb ...
Page 164 MAINTENANCE WORK ON FRAME AND ENGINE – Position the lug of the lamp cover in the notch. Engage the latch   – Check that the lighting is functioning properly. 400422-10 – Position the rubber holder  – Fold down the combination instrument. Position the lug in the rubber retainer.
Page 165: Changing The High Beam Lamp
MAINTENANCE WORK ON FRAME AND ENGINE Changing the high beam lamp 9.61 Note Damage to reflector Reduced luminance. – Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean the bulb and keep it free of grease before mounting.
Page 166 MAINTENANCE WORK ON FRAME 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 / base PX26d) ( p.
Page 167 MAINTENANCE WORK ON FRAME AND ENGINE – Position the lug of the lamp cover in the notch. Engage the latch.  – Check lighting function. 400422-11 – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. –...
Page 168: Changing The Parking Light Bulb
MAINTENANCE WORK ON FRAME AND ENGINE Changing the parking light bulb 9.62 Note Damage to reflector Reduced luminance. – Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean the bulb and keep it free of grease before mounting.
Page 169 MAINTENANCE WORK ON FRAME AND ENGINE – Pull the parking light carefully out of the holder.  – Remove the light bulb. – Position a new light bulb in the holder. Parking light (W5W/ base W2.1x9.5d) ( p. 219) – Carefully position the holder with the bulb in the holder in the headlight.
Page 170: Checking The Headlamp Setting
MAINTENANCE WORK ON FRAME AND ENGINE – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. – Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 100745-12 Checking the headlamp setting 9.63 –...
Page 171: Adjusting Headlamp Range
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting headlamp range 9.64 – Check the headlamp setting. ( p. 168) – Adjust the beam distance of the headlight by turning screw  Guideline A motorcycle with rider, including the luggage and a passenger (where applicable) the light cut off must be aligned exactly on the lower mark (when checking headlight adjustment).
Page 172 MAINTENANCE WORK ON FRAME AND ENGINE Loss of a black ignition key (second black ignition key available): The following procedure deactivates all activated black ignition keys that are not included in the procedure. – Press the emergency OFF switch into the position –...
Page 173 MAINTENANCE WORK ON FRAME AND ENGINE The existing black ignition key is reactivated. Loss of both black ignition keys (no black ignition key available): This procedure is important to prevent misuse of the lost black ignition key. – Press the emergency OFF switch into the position –...
Page 174 MAINTENANCE WORK ON FRAME AND ENGINE – Switch off the ignition by turning the orange programming key to the OFF position – Pull out the orange programming key. – Insert the black ignition key in the ignition lock. – Switch off the ignition by turning the black programming key to the position ON EFI warning lamp (MIL) lights up, switches off, and then starts to flash.
Page 175: Cooling System
MAINTENANCE WORK ON FRAME AND ENGINE Cooling system 9.66 The water pump with a 3D water pump wheel in the engine ensures forced circulation of  the coolant. The heat exchanger enables faster warming of the engine oil at the start of a journey and better heat dissipation for the engine oil during the journey.
Page 176: Filling The Cooling System Compensating Tank
MAINTENANCE WORK ON FRAME AND ENGINE Condition The engine is cold. The radiator is completely full. – Rest the motorcycle on its side stand on a horizontal surface. – Check the coolant level in the compensating tank. The coolant level must be between MIN and MAX. »...
Page 177 After draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model type. This is the only way of ensuring that the cooling system is filled without air bubbles. (Your authorized KTM RC8 workshop will be pleased to help.)
Page 178: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON FRAME AND ENGINE 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.
Page 179: Correcting Fluid Level Of Hydraulic Clutch
MAINTENANCE WORK ON FRAME AND ENGINE – Check the fluid level. The fluid level must be between the MIN and MAX markings. » If the coolant level does not meet specifications: – Correct the fluid level of the hydraulic clutch. ( p.
Page 180: Adjusting The Play In The Throttle Cable
Adjusting the play in the throttle cable 9.72 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the basic position. – Push back protective cover  – Loosen counter nut ...
Page 181: Handlebar Height
The installed throttle grip has the marking 3081. The supplied throttle grip has the marking 5209. Info Resetting the throttle cable play is necessary after replacement has been carried out. It is imperative to use the KTM diagnostics tool for this. 100784-10 Handlebar height 9.74...
Page 182 MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the high position of the handlebar stubs: – Loosen screw  Info Loosen the screw several turns to prevent damage to the fork lacquer when moving the handlebar stub. – Remove screw  100756-10 –...
Page 183 MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the low position of the handlebar stubs: – Loosen screw  Info Loosen the screw several turns to prevent damage to the fork lacquer when moving the handlebar stub. 100759-10 – Remove screw with distance sleeve ...
Page 184: Rear Frame Position
MAINTENANCE WORK ON FRAME AND ENGINE – Tighten the screw. Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) – Repeat the adjustments on the other handlebar stub. – Move the handlebar to and fro over the entire steering range. »...
Page 185 MAINTENANCE WORK ON FRAME AND ENGINE – Remove the seat. ( p. 148) – Remove screws with the bushings.  100762-10 Setting a higher seat position: – Remove screw with washer on the left and right sides of the vehicle. ...
Page 186 MAINTENANCE WORK ON FRAME AND ENGINE – Mount the screw and washer on the left and right sides of the vehicle, but do not tighten. 100764-01 – Remove screw with washer on the left and right sides of the vehicle. ...
Page 187 MAINTENANCE WORK ON FRAME AND ENGINE Setting a lower seat position: – Remove screw with washer on the left and right sides of the vehicle.  – Push the rear end down until the drill holes of the frame are level with the upper rear drill holes of the rear.
Page 188 MAINTENANCE WORK ON FRAME AND ENGINE – Tighten screw on the left and right sides of the vehicle.  Guideline Screw, subframe 20 Nm Loctite ® 243™ (14.8 lbf ft) 100765-12 – When you screw in the rear left fixing screw, the plug-in cable binder is pushed out ...
Page 189: Checking The Engine Oil Level
MAINTENANCE WORK ON FRAME AND ENGINE Checking the engine oil level 9.78 Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Remove oil dipstick . Check the engine oil level in the measurement range. ...
Page 190: Draining Engine Oil, Cleaning Oil Screens
MAINTENANCE WORK ON FRAME AND ENGINE Draining engine oil, cleaning oil screens 9.80 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with lukewarm water.
Page 191 MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws  – Take off the left exhaust cover  100771-10 – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil drain plug with the magnet, O-rings and oil screen.
Page 192 MAINTENANCE WORK ON FRAME AND ENGINE – Thoroughly clean the magnet and oil screen of the oil drain plug.   100773-10 – Mount and tighten the oil drain plugs with the magnet, O-rings and oil screen. Guideline Oil drain plug M20x1.5 20 Nm (14.8 lbf ft)
Page 193: Removing The Oil Filter
MAINTENANCE WORK ON FRAME AND ENGINE – Position the left exhaust cover  – Mount and tighten screws  Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) 100771-10 Removing the oil filter 9.81 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –...
Page 194 MAINTENANCE WORK ON FRAME AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove screws .
Page 195: Installing The Oil Filter
MAINTENANCE WORK ON FRAME AND ENGINE Installing the oil filter 9.82 – Insert oil filter  – Lubricate the O-ring of the oil filter cover. Mount oil filter cover  – Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 100776-10 Filling up with engine oil...
Page 196 MAINTENANCE WORK ON FRAME AND ENGINE Engine oil (1st 3.00 l (3.17 qt.) External Engine oil (SAE quantity) temperature: 5W/40) ( p. 228) < 0 °C (< 32 °F) – Replace the oil dipstick  Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
Page 197: Adding Engine Oil
MAINTENANCE WORK ON FRAME AND ENGINE – Start the engine and check that it is oil-tight. – Check the engine oil level. ( p. 187) Adding engine oil 9.84 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –...
Page 198 MAINTENANCE WORK ON FRAME AND ENGINE 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 without an effective exhaust extraction system.
Page 199: Troubleshooting
OFF switch defective – Check the emergency OFF switch. – Safety start system defective Read out the trouble code memory using the KTM diagnostics tool. – Immobilizer active Read flash code of immobilizer. – EFI control unit not activated Activate the EFI control unit.
Page 200 Clean plug connector and treat with contact dized spray. – Fault in fuel injection system Read out the trouble code memory using the KTM diagnostics tool. – Fuel pump control defective Read out the trouble code memory using the KTM diagnostics tool. –...
Page 201 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 187) – Engine oil too thin (viscosity) Change the engine oil and filter, clean the oil screen. p. 187) –...
Page 202: Immobilizer Blink Code
IMMOBILIZER BLINK CODE Flash code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Flash code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition Immobilizer control unit antenna fault Flash code of immobilizer indica-...
Page 203 IMMOBILIZER BLINK CODE Flash code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition Immobilizer control unit not activated Flash code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Flash code of immobilizer indica-...
Page 204: Engine Control Blink Code
ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 45 EFI warning lamp (MIL) four long flashes and five short flashes Error level condition Heating lambda sensor cylinder 1, sensor 1 - interruption/short circuit to ground Heating lambda sensor cylinder 1, sensor 1 - input signal too high Blink code EFI warning lamp (MIL) 46 EFI warning lamp (MIL) flashes four times long and six times briefly Error level condition...
Page 205 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 12 EFI warning lamp (MIL) one long flash and two short flashes Error level condition Coolant temperature sensor - input signal too low Coolant temperature sensor - input signal too high Blink code EFI warning lamp (MIL) 06 EFI warning lamp (MIL) six short flashes Error level condition...
Page 206 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 34 EFI warning lamp (MIL) three long flashes and four short flashes Error level condition Injection valve cylinder 2 - malfunction in circuit Blink code EFI warning lamp (MIL) 07 EFI warning lamp (MIL) seven short flashes Error level condition Throttle position sensor circuit B - input signal too low Throttle position sensor circuit B - input signal too high...
Page 207 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 54 EFI warning lamp (MIL) five long flashes and four short flashes Error level condition Secondary air valve - interruption/short circuit to ground Secondary air valve - input signal too high Blink code EFI warning lamp (MIL) 49 EFI warning lamp (MIL) four long flashes and nine short flashes Error level condition...
Page 208 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 68 EFI warning lamp (MIL) six long flashes and eight short flashes Error level condition Manifold absolute pressure sensor cylinder 1 - connection leaks Blink code EFI warning lamp (MIL) 69 EFI warning lamp (MIL) six long flashes and nine short flashes Error level condition Manifold absolute pressure sensor cylinder 2 - connection leaks...
Page 209 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 15 EFI warning lamp (MIL) one long flash and five short flashes Error level condition Input signal from roll angle sensor too low Input signal from roll angle sensor too high Blink code EFI warning lamp (MIL) 81 EFI Warning lamp (MIL) flashes 8x long, 1x short Error level condition...
Page 210: Cleaning
CLEANING 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 211 CLEANING Warning Danger of accidents Reduced braking efficiency 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.
Page 212: Protective Treatment For Winter Operation
PROTECTIVE TREATMENT FOR WINTER OPERATION 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. –...
Page 213: Storage
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle rear end. ( p. 97) –...
Page 214: Putting Into Operation After Storage
STORAGE 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 –...
Page 215: Technical Data - Engine
TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 42 mm (1.65 in) Exhaust...
Page 216: Capacity- Engine Oil
TECHNICAL DATA - ENGINE 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…...
Page 217: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 3 Nm (2.2 lbf ft) Loctite 243™...
Page 218 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, starter motor 10 Nm (7.4 lbf ft) ® Screw, stator clamp 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, valve cover 10 Nm (7.4 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) ®...
Page 219 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) Cylinder head screw M11x1.5 Tightening sequence:...
Page 220: Technical Data - Frame
TECHNICAL DATA - FRAME 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 120 mm (4.72 in) Brake system Front Twin floating disc with radial mount, 4-piston calipers Rear...
Page 221: Lighting Equipment
TECHNICAL DATA - FRAME Steering head angle 66.7° Wheelbase 1,425 mm (56.1 in) Seat height, unloaded Lower frame rear position 805 mm (31.69 in) Upper frame rear position 825 mm (32.48 in) Ground clearance, unloaded 110 mm (4.33 in) Weight without fuel approx. 184 kg (406 lb.) Maximum permissible front axle load 150 kg (331 lb.)
Page 222: Tires
120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 18.3 Total fuel tank capacity, approx. 16.5 l (4.36 US gal) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p.
Page 223: Technical Data - Fork
TECHNICAL DATA - FORK Fork part number 05.18.7E.10 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...
Page 224: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 17.18.7E.10 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...
Page 225 TECHNICAL DATA - SHOCK ABSORBER Gas pressure 10 bar (145 psi) Static sag 10… 15 mm (0.39… 0.59 in) Riding sag 30… 35 mm (1.18… 1.38 in) Inbuilt length 290 mm (11.42 in) Shock absorber oil ( p. 229) SAE 2.5...
Page 226: Technical Data - Frame Tightening Torques
TECHNICAL DATA - FRAME TIGHTENING TORQUES ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ – Remaining frame bolts 5 Nm (3.7 lbf ft) ® Screw, brake fluid reservoir of rear brake 5 Nm (3.7 lbf ft) Loctite 243™...
Page 227 TECHNICAL DATA - FRAME TIGHTENING TORQUES ® Nut, forked bracket on footbrake pedal 30 Nm (22.1 lbf ft) Loctite 243™ – Remaining chassis nuts 30 Nm (22.1 lbf ft) – Remaining chassis screws 25 Nm (18.4 lbf ft) ® Screw of rear brake caliper 22 Nm (16.2 lbf ft) Loctite 243™...
Page 228 TECHNICAL DATA - FRAME TIGHTENING TORQUES – Remaining chassis nuts 50 Nm (36.9 lbf ft) – Remaining chassis screws 45 Nm (33.2 lbf ft) ® Screw, connecting lever, shock absorber 45 Nm (33.2 lbf ft) Loctite 243™ deflector – Screw, engine bearer 45 Nm (33.2 lbf ft) ®...
Page 229: Substances
– Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 230 SAE ( p. 233) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Fully synthetic engine oil Supplier ® Motorex –...
Page 231 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
Page 232 SUBSTANCES Super unleaded (ROZ 98 / RON 98 / PON 94) According to – DIN EN 228 (ROZ 98 / RON 98 / PON 94)
Page 233: Auxiliary Substances
AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and polishing materials for metal, rubber and plastic Specification –...
Page 234 AUXILIARY SUBSTANCES Motorcycle cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Specification – ® KTM recommends Motorex products. Supplier ®...
Page 235: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, 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.
Page 236 INDEX Braking ........88 INDEX Accessories .
Page 237 INDEX LAP menu, LAP BLANK T button ....48, 58, 60 Emergency OFF switch ......22 LAP/BESTLAP/LastLap menu .
Page 238 INDEX Fork ........Horn button .
Page 239 INDEX removing ........149 Maximum speed displaying ........62 Protective treatment for winter operation .
Page 240 INDEX Seat lock ........74 Steering lock .
Page 241 INDEX Vehicle identification number ......16 Vehicle level ....... . . front, adjusting .
Page 242 *3211375en* 3211375en 01/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

KTM 1190 RC8 R EU/UK 2009 Owner's Manual

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