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OWNER'S MANUAL 2008 1190 RC8 EU 1190 RC8 AUS/UK 1190 RC8 FR 1190 RC8 JP ART. NO. 3211250en...
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KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing and other errors.
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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.
Page 5: Table Of Contents

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 ... 16 Chassis number/type label ... 16 Key number ...
Page 6: Table Of Contents

Important service tasks to be carried out by an authorized KTM-RC8 workshop..91 Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) ... 94 MAINTENANCE WORK ON CHASSIS AND ENGINE... 95 Jacking up motorcycle front... 95 Taking front of motorcycle off work stand...
Page 7: Table Of Contents

CONTENTS Adjusting shift lever... 116 Adjusting the footbrake pedal stub ... 120 Adjusting the footbrake pedal ... 121 checking for chain dirt ... 121 Cleaning the chain... 122 Checking the chain tension ... 123 Adjusting the chain tension ... 124 Checking rear sprocket / engine sprocket for wear ...
Page 8: Table Of Contents

Topping up engine oil ... 192 TROUBLESHOOTING... 194 IMMOBILIZER FLASH CODE ... 197 ENGINE CONTROL FLASH CODE... 198 CLEANING... 202 Cleaning motorcycle ... 202 CONSERVATION FOR WINTER OPERATION ... 204 Conservation for winter operation ... 204 STORAGE ... 205 Storage... 205 Putting into operation after storage ...
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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 2 I MPORTANT 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.
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Responsible behavior in handling the motorcycle can help to avoid such problems and con- flicts. To ensure the future of motorcycle sport, make sure you use the motorcycle legally, demonstrate a consciousness for the environ-...
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Be sure to read these operating instructions carefully and completely before taking your first ride. They contain much information and tips that will help you to operate and handle your motorcycle. Only in this way will you find out how to adjust the motorcycle best for your own use and how to protect yourself from injury.
Page 14: View Of Vehicle, View Of Vehicle, Front Left Side

VIEW OF VEHICLE 3 V IEW OF VEHICLE View of vehicle, front left side 700243-10...
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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 700242-10...
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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, Chassis Number/type Label, Key Number

LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number/type label 700231-01 Key number 700222-01 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. ...
Page 19: Engine Number, Fork Part Number

LOCATION OF SERIAL NUMBERS Engine number 700223-01 Fork part number 700224-01 The engine number is stamped on the right side of the engine.  The fork part number is stamped on the inner side of the fork stub. ...
Page 20: Shock Absorber Part Number, Steering Damper Part Number

LOCATION OF SERIAL NUMBERS Shock absorber part number 700225-01 Steering damper part number 700226-01 The shock absorber part number is stamped on the upper part of the shock absorber  above the adjusting ring towards the rear. The steering damper part number is stamped on the top of the steering damper.
Page 21: Operating Elements, Clutch Lever, Hand Brake Lever

OPERATING ELEMENTS 5 O PERATING ELEMENTS Clutch lever 700227-01 Hand brake lever 700228-01 The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulic and self-adjusting. The handbrake lever is fitted on the right side of the handlebar. ...
Page 22: Light Switch, Headlight Flasher Switch

OPERATING ELEMENTS Light switch 700230-13 Headlight flasher switch 700232-01 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.
Page 23: Flasher Switch, Horn Button

OPERATING ELEMENTS Flasher switch 700230-12 Horn button 700230-11 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.
Page 24: Ignition/steering Lock, Emergency Off Switch

OPERATING ELEMENTS Ignition/steering lock 700234-01 Emergency OFF switch 700229-11 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.
Page 25: Electric Starter Button

OPERATING ELEMENTS Electric starter button 700229-12 The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in neutral position pressed – In this position, the electric starter is operated. • Electric starter button ...
Page 26: Combination Instrument - Overview

OPERATING ELEMENTS Combination instrument - overview 5.10 400430-10 display ( S. 27) Function buttons Indicator lamps ( S. 29) info display ( S. 28)
Page 27: Combination Instrument - Function Buttons On Handlebar

OPERATING ELEMENTS Combination instrument - function buttons on handlebar 5.11 600642-10 The Mode button is fitted on the handlebar, front left.  The Lap button is fitted on the handlebar, rear left. ...
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, TripDist, TripTime, AvgSpeed mode. In RACE mode, the info display switches to LAPSTOGO, LastLap, ±Last, ±Best mode.
Page 29: Display

OPERATING ELEMENTS display 5.13 400430-12 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

OPERATING ELEMENTS info display 5.14 400430-13 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.
Page 31: Indicator Lamps

OPERATING ELEMENTS Indicator lamps 5.15 400430-14 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.
Page 32: Notes/warnings On The Combination Instrument

OPERATING ELEMENTS Notes/warnings on the combination instrument 5.16 400476-01 400471-01 LOW FUEL appears on the info display if the minimum range falls below the specified value. Distance 25 km (15.5 mi) LOW BATTERY appears on the info display if the battery voltage falls below the specified value.
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OPERATING ELEMENTS 400472-01 400474-01 400469-01 SERVICE IN xxx KM(MPH) appears on the info display if the distance to the next service falls below the specified value. Distance 500 km (310.7 mi) HIGH TEMP appears on the info display if the coolant temperature rises above the specified value.
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OPERATING ELEMENTS 400470-01 400468-01 400467-01 REAR SENSOR appears on the info display if the coolant temperature sensor of the rear cyclinder is defective. 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) ICE appears on the info display if the external temperature falls below the specified value.
Page 35: Odo Menu

OPERATING ELEMENTS ODO menu 5.17 400438-01 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. TripDist shows the distance covered since the last reset. For example, between two refueling stops.
Page 36: Fueldistance Menu

OPERATING ELEMENTS FUELDISTANCE menu 5.18 400441-01 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 37: Fuelrange Menu

OPERATING ELEMENTS FUELRANGE menu 5.19 400477-01 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.
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5.20 400443-01 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.
Page 39: Lapstogo Menu

OPERATING ELEMENTS LAPSTOGO menu 5.21 400444-01 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 40: Topspeed Menu

OPERATING ELEMENTS TOPSPEED menu 5.22 400445-01 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 41: Lap/bestlap/lastlap Menu

LAP/BESTLAP/LastLap menu 5.23 400446-01 Condition • The ignition is on. • 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.
Page 42: Lap/bestlap/topspeed Menu

LAP/BESTLAP/TopSpeed menu 5.24 400447-01 Condition • The ignition is on. • 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.
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5.25 400448-01 Condition • The ignition is on. • 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.
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5.26 400449-01 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button 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.
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OPERATING ELEMENTS CHANGE MODE menu 5.27 400475-01 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button or the button CHANGE MODE in the info display. On the CHANGE MODE menu, you can select between ROAD and RACE mode.
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OPERATING ELEMENTS SET CLOCK menu 5.28 400455-01 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button once until the symbol You can set the clock on the SET CLOCK menu.
Page 47: Settings Menu

On the TRIP F RESET menu, you set the reaction time of the fuel reserve display to changes of the fuel level. On the S.LEARN TPMS menu, only a KTM-RC8 workshop can make changes. On the BACK… menu, you switch back to the SET‑UP menu. The symbol ...
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OPERATING ELEMENTS SHIFT RPMS menu 5.30 400460-01 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. On the SHIFT RPMS menu, you can activate the shift warning light.
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OPERATING ELEMENTS LAP menu, LAP BLANK T button 5.31 400461-01 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 once until the symbol ...
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OPERATING ELEMENTS SET NUM LAPS menu 5.32 400462-01 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 twice until the symbol ...
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OPERATING ELEMENTS TRIP F RESET menu 5.33 400463-01 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 three times until the symbol ...
Page 52: Units Menu

UNITS menu 5.34 400458-01 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol On the SET KM/MILES menu, you can set the units for measuring speed and distance.
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OPERATING ELEMENTS SET KM/MILES menu 5.35 400464-01 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 ...
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OPERATING ELEMENTS SET °C/°F menu 5.36 400465-01 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 ...
Page 55: Options Menu

OPTIONS menu 5.37 400459-01 Condition • The ignition is on. • The motorcycle is standing. – Press the button and the button – Press the button four times until the symbol On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as accessory).
Page 56: Tpms Menu

OPERATING ELEMENTS TPMS menu 5.38 400478-01 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. On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as accessory).
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Display Press the button . ODO menu no function 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 ...
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OPERATING ELEMENTS Table of functions Display Press the button . FUELDISTANCE no function menu FUELRANGE menu no function DISTANCE TO no function Next Service menu LAPSTOGO menu no function TOPSPEED menu no function LAP/BESTLAP/Last- The next lap is dis- Lap menu played LAP/BESTLAP/ The next lap is dis- TopSpeed menu...
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OPERATING ELEMENTS Table of functions Display Press the button . Total distance no function menu in Race mode RACEODO SET‑UP menu The arrow moves up The arrow moves CHANGE MODE Changes the menu menu SET CLOCK menu increases the value SETTINGS menu The arrow moves up The arrow moves SHIFT RPMS menu increases the value increases the value...
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OPERATING ELEMENTS Table of functions Display Press the button . TRIP F RESET menu increases the value UNITS menu The arrow moves up The arrow moves SET KM/MILES Changes the unit menu SET °C/°F menu Changes the unit OPTIONS menu The arrow moves up The arrow moves TPMS menu Switches the tire pressure display...
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OPERATING ELEMENTS Table of conditions and activability Display • The igni- tion is on. • ROAD mode ODO menu FUELDISTANCE menu FUELRANGE menu DISTANCE TO Next Service menu LAPSTOGO menu TOPSPEED menu LAP/BESTLAP/LastLap menu LAP/BESTLAP/TopSpeed menu Total distance menu in Race mode RACEODO SET‑UP menu CHANGE MODE menu SET CLOCK menu SETTINGS menu...
Page 62: Displaying Lap Times

• The motor- • RACE mode cycle is standing. • ROAD mode Condition The ignition is on. The motorcycle is standing. RACE mode Menu can be • The igni- • The igni- activated tion is on. tion is on. •...
Page 63: Displaying Maximum Speed

– Press the MODE button briefly. Next display mode Condition The ignition is on. The motorcycle is standing. RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in the info display. LAP01 appears on the left of the info display.
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OPERATING ELEMENTS Setting ROAD or RACE mode 5.42 400475-01 Setting the clock with SET CLOCK 5.43 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button or the button CHANGE MODE in the info display.
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Press the button briefly and repeatedly until the symbol info display. – Press the MODE button briefly. Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol ...
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OPERATING ELEMENTS – 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. –...
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Setting the blank time of the LAP button LAP BLANK T 5.45 400461-01 – Press the MODE button briefly. Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol –...
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Press the button briefly and repeatedly until the symbol info display. – Press the MODE button briefly. Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button twice until the symbol ...
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OPERATING ELEMENTS Setting fuel reserve display TRIPF RESET 5.47 400463-01 – Press the MODE button briefly. 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 ...
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OPERATING ELEMENTS Setting kilometers/miles SET KM/MILES 5.48 Info Making a country-specific setting. 400464-01 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 ...
Page 71: Switching External Temperature Display On/off

OPERATING ELEMENTS Setting temperature unit SET °C/°F 5.49 400465-01 Switching external temperature display on/off 5.50 Condition The ignition is on. The motorcycle is standing. – Press the button and the button – Press the button three times until the symbol –...
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OPERATING ELEMENTS 400466-01 – Press the button and the button – Press the button four times until the symbol – Press the button once until the symbol play. – Press the MODE button briefly. You see ENABLED or DISABLED on the info display. –...
Page 73: Opening The Filler Cap

OPERATING ELEMENTS 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.
Page 74: Closing The Filler Cap, Supporting Strap

OPERATING ELEMENTS Closing the filler cap 5.52 700236-01 Supporting strap 5.53 700244-01 – Close the filler cap. Push down the filler cap slightly until the lock closes. – Remove the ignition key and close the cover. The supporting strap is provided for the passenger to hold on to. ...
Page 75: Seat Lock, Tool Set

OPERATING ELEMENTS Seat lock 5.54 700245-01 Tool set 5.55 700310-01 The seat lock is behind the seat.  It can be locked with the ignition key. The tool set is in the storage compartment under the seat. ...
Page 76: Helmet Lock, Passenger Footrests

OPERATING ELEMENTS Helmet lock 5.56 700337-01 Passenger footrests 5.57 700247-01 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen. Warning Danger of accidents Impairment of handling characteristics and vehicle operation by a fitted helmet lock or helmet.
Page 77: Shift Lever

OPERATING ELEMENTS Shift lever 5.58 700239-01 700238-01 The shift lever is mounted on the left of the engine.  The gear positions can be seen in the picture. The neutral or idle position is between the first and second gear. ...
Page 78: Foot Brake Pedal, Side Stand

OPERATING ELEMENTS Foot brake pedal 5.59 700237-01 Side stand 5.60 700258-01 The footbrake pedal is in front of the right footrest.  The footbrake pedal operates the rear brake. The side stand is coupled with the safety start system; see the riding instructions. ...
Page 79: Tips On Putting Into Operation, Advice On First Use

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 80: 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 81: 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.
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TIPS 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 83: 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. – Check the engine oil level. ( S.
Page 84: Starting

RIDING INSTRUCTIONS 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. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
Page 85: Starting Up

Press the starter for a maximum of 5 seconds without a break. Wait at least 5 seconds before trying to start again. This motorcycle is equipped with a safety start system. The engine will only start if in neutral or, if a gear is engaged, when the clutch lever is pulled. If the side- stand is out and the machine is in gear and you release the clutch lever, the engine stops.
Page 86: Shifting, Riding

RIDING INSTRUCTIONS Shifting, riding 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. –...
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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 slipped baggage.
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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. 700238-01 –...
Page 89: 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 90: Stopping, Parking

RIDING INSTRUCTIONS 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 brak- ing. – When braking, first throttle back and then apply the front and rear brakes at the same time. –...
Page 91: Refueling

– 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.
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– Do not allow fuel to get into the ground water, the ground, or the sewage system. Info This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel only. 700321-01 –...
Page 93: Greasing And Service Table, Ktm-rc8 Workshop

GREASING AND SERVICE TABLE 8 G REASING AND SERVICE TABLE Important service tasks to be carried out by an authorized KTM-RC8 workshop. Engine Change the engine oil and filter, clean the oil screen. Check the valve clearance and adjust if necessary. ...
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GREASING AND SERVICE TABLE Attachments Check bowden cables for damage, smooth operation, kink-free routing and adjustment. Check the fluid level of the hydraulic clutch. ( Check the air filter and change if necessary. Clean the air filter box. Drain the drainage hose of the air filter box. Check cables for damage and kink-free routing. ...
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GREASING AND SERVICE TABLE Chassis Check the steering head bearing and adjust if necessary. Check the swingarm bearing. Check deflector. Check the eccentric shaft adjustment. Check all screws to make sure they are tight. Wheels Check the tire condition. ( Checking the tire air pressure.
Page 96: Important Service Tasks To Be Carried Out By An Authorized Ktm-rc8 Workshop. (as Additional Job)

GREASING AND SERVICE TABLE Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) Completely service fork. Completely service shock absorber. Clean and grease the steering head bearing and sealing elements. Clean battery poles and treat with contact grease.
Page 97: Maintenance Work On Chassis And Engine, Jacking Up Motorcycle Front

Move the handlebar to the straight-ahead position. Align the work stand at the front with the adapters to the fork legs. Work stand front (61029055300) Info Always jack up the rear of the motorcycle first. – Jack up the motorcycle at the front. S. 96)
Page 98: Jacking Up Motorcycle Rear, Taking Rear Of Motorcycle Off Work Stand

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.
Page 99: Fork/shock Absorber, Adjusting Compression Damping Of Fork

MAINTENANCE WORK ON CHASSIS AND ENGINE Fork/shock absorber 700252-01 Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when the load shifts very fast.
Page 100: Adjusting Rebound Damping Of Fork

MAINTENANCE WORK ON CHASSIS AND ENGINE 700253-01 Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior. An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the zero position.
Page 101: Adjusting Spring Preload Of Fork

MAINTENANCE WORK ON CHASSIS AND ENGINE 700347-01 Adjusting spring preload of fork Info The spring preload defines the initial situation of the spring process of the fork. An optimally adjusted spring preload is adapted to the rider's weight and ensures a compromise between easy handling and stabil- ity.
Page 102: Bleeding Fork Legs

Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work. However, you should also adjust the rebound damping when you alter the spring preload. – Lean the motorcycle on the side stand. 5 turns 5 turns 3 turns...
Page 103: Compression Damping Of The Shock Absorber, Adjusting The Low-speed Compression Damping Of The Shock Absorber

(Dual Compression Control).  The term low and high speed refers to the movement of the shock absorber during compres- sion and not the riding speed of the motorcycle. The low and high speed adjustment works for all areas. ...
Page 104

MAINTENANCE WORK ON CHASSIS AND ENGINE Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. 700255-01 – Turn the adjusting screw clockwise with a screwdriver up to the last perceptible  click. Info Do not loosen nut ...
Page 105: Absorber

MAINTENANCE WORK ON CHASSIS AND ENGINE 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 mainte- nance on it yourself.
Page 106: Adjusting Rebound Damping Of The Shock Absorber, Adjusting Spring Preload Of Shock Absorber

MAINTENANCE WORK ON CHASSIS AND ENGINE 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 mainte- nance on it yourself.
Page 107

MAINTENANCE WORK ON CHASSIS AND ENGINE 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 stabil- ity.
Page 108

MAINTENANCE WORK ON CHASSIS AND ENGINE 700341-11 – Turn the adjusting ring clockwise and tension it to the specified value. Guideline Spring preload Comfort Standard Sport full payload Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload. –...
Page 109: Steering Damper, Adjusting The Steering Damper

MAINTENANCE WORK ON CHASSIS AND ENGINE Steering damper 9.15 700339-01 Adjusting the steering damper 9.16 Info The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load. In contrast to other damping elements, the steering damper is adjusted with the damping element open. 700339-10 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.
Page 110

MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 Recommended range for use Standard Info Do not change the adjustment of the steering damper during the journey! After adjusting the steering damper, check the steering for smooth operation, making sure that the handlebar can be moved from extreme left to extreme right without a tendency to lock.
Page 111: Vehicle Level

MAINTENANCE WORK ON CHASSIS AND ENGINE Vehicle level 9.17 700333-01 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.
Page 112

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting vehicle level, front 9.18 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. 700352-01 –...
Page 113

MAINTENANCE WORK ON CHASSIS AND ENGINE 700353-01 Adjusting vehicle level at rear 9.19 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. –...
Page 114

MAINTENANCE WORK ON CHASSIS AND ENGINE 700331-01 700332-01 – Loosen screw but do not remove it.  – Turn the eccentric shaft to the desired position using the tool from the tool set.  Guideline Standard Maximum adjustment range between HIGH - LOW Open end wrench SW 38 (69012021000) Info...
Page 115: Footrest Position, Adjusting Footrest Position

MAINTENANCE WORK ON CHASSIS AND ENGINE 700334-01 Footrest position 9.20 700328-01 Adjusting footrest position 9.21 Info The footrest position must be identical on the left and the right. – Tighten screw  Guideline Remaining chassis screws 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 CHASSIS AND ENGINE 700307-01 700308-01 700306-01 – Remove screws  – Position the footrest bracket with spacers Guideline Standard Info The adjustable footrest bracket enables a more comfortable lower footrest posi- tion or a sporting upper footrest position. –...
Page 117

MAINTENANCE WORK ON CHASSIS AND ENGINE 700309-01 – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( S. 116) – Adjust the footbrake pedal. ( S. 121)
Page 118: Adjusting Shift Lever Stub, Adjusting Shift Lever

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting shift lever stub 9.22 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. – Remove the screw with the shift lever stub. ...
Page 119

MAINTENANCE WORK ON CHASSIS AND ENGINE 700343-01 – 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 ...
Page 120

MAINTENANCE WORK ON CHASSIS AND ENGINE 0 0 A 0 0 B 0 0 C 400479-10 – 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 ...
Page 121

MAINTENANCE WORK ON CHASSIS AND ENGINE 700344-01 – 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 ...
Page 122: Adjusting The Footbrake Pedal Stub

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the footbrake pedal stub 9.24 700305-01 – Remove the screw with the footbrake pedal stub.  – Position the footbrake pedal stub with the screw in one of the holes desired lever length. Guideline Standard –...
Page 123: Adjusting The Footbrake Pedal, Checking For Chain Dirt

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the footbrake pedal 9.25 700345-01 700346-01 checking for chain dirt 9.26 – Check the chain for loose dirt. » If the chain is very dirty: – Clean the chain. ( S. 122) – Use the tool to press in the anti-rotation lock ...
Page 124: Cleaning The Chain

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. –...
Page 125: Checking The Chain Tension

On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. 700322-01 – Lean the motorcycle on the side stand. – Shift into neutral. –...
Page 126: Adjusting The Chain Tension

MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
Page 127

MAINTENANCE WORK ON CHASSIS AND ENGINE 700323-01 – Loosen nut  – Loosen nuts  – Adjust chain tension by turning the adjustment screws Guideline Chain tension 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 CHASSIS AND ENGINE Checking rear sprocket / engine sprocket for wear 9.30 100132-10 – 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

Info New chains wear out faster on old, worn sprockets. For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM-RC8 workshop, where they have the nec- essary special tools.  15 kg (33 lb.)
Page 130: Checking Chain Sliding Guard, Checking Front Brake Discs

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. 100135-10 – Check the chain sliding guard for wear at the opening. »...
Page 131: Checking Rear Brake Disc, Adjusting The Basic Position Of The Handbrake Lever

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. 400480-10 Adjusting the basic position of the handbrake lever 9.35 700260-01 –...
Page 132

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. 700261-01 Topping up brake fluid of front brake ...
Page 133

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. Warning Environmental hazard Problem materials cause environmental damage.
Page 134: Brake Linings, Checking The Front Brake Linings

MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
Page 135: Checking Rear Brake Fluid Level

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. – Check the brake linings for minimum thickness ...
Page 136

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. – Stand the vehicle upright. –...
Page 137: Checking The Rear Brake Linings

700265-01 Checking the rear brake linings 9.42 Warning Danger of accidents Reduced braking caused by worn brake linings. – Have worn brake linings replaced immediately in an authorized KTM-RC8 workshop. – Stand the vehicle upright. – Remove screw cover with membrane ...
Page 138

If the minimum thickness is less than specified: – Change the rear brake linings. – Jack up the motorcycle rear end. ( – Jack up the motorcycle at the front. ( – Remove the screws from both brake calipers.  –...
Page 139

MAINTENANCE WORK ON CHASSIS AND ENGINE 700272-10 Fitting front wheel 9.44 200487-10 – Loosen screws and   – 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 140

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. ( –...
Page 141

MAINTENANCE WORK ON CHASSIS AND ENGINE 700311-01 700312-01 – Remove nut . Remove chain adjuster  – 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 brake disc and the wheel rim.
Page 142

MAINTENANCE WORK ON CHASSIS AND ENGINE fitting the rear wheel 9.46 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.
Page 143

MAINTENANCE WORK ON CHASSIS AND ENGINE 700313-01 700314-01 – 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.
Page 144

Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Take the rear of the motorcycle off the work stand. ( – Check the chain tension. ( S. 123) ...
Page 145

MAINTENANCE WORK ON CHASSIS AND ENGINE Checking rear hub shock absorbers 9.47 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. 700274-01 Tire condition checking 9.48...
Page 146

Info The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces. 700267-01 –...
Page 147: Checking Tire Air Pressure

MAINTENANCE WORK ON CHASSIS AND ENGINE 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. 700268-01 – Remove dust cap.
Page 148: Removing The Seat, Fitting The Seat

MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat 9.50 700245-01 Fitting the seat 9.51 700269-01 – Insert the ignition key in the seat lock – Raise the rear of the seat, push it towards the rear, and remove it upwards. –...
Page 149: Removing Passenger Seat, Fitting The Passenger Seat

MAINTENANCE WORK ON CHASSIS AND ENGINE Removing passenger seat 9.52 700246-01 Fitting the passenger seat 9.53 700275-01 – Remove the seat. ( S. 146) – Operate lever  – Take off the passenger seat toward the top.  – Position the passenger seat in the space provided. –...
Page 150: Mounting Helmet Lock On Vehicle

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) –...
Page 151

Pull the battery upwards out of the battery rack. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety equipment can be damaged. The vehicle is then no longer safe to ride.
Page 152

MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery 9.56 700279-01 700277-11 – 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 ...
Page 153

MAINTENANCE WORK ON CHASSIS AND ENGINE 700276-11 Recharging the battery 9.57 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. –...
Page 154

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 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.
Page 155: Changing The Main Fuse

After charging the battery, switch off the battery charger. Reconnect the battery. Guideline The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. – Fit the seat. ( S. 146) on the battery casing.
Page 156

 – Fit a new main fuse. Fuse (58011109130) ( S. 213) Info If the new fuse burns out, contact an authorized KTM-RC8 workshop. – Attach the protection covers  – Fit the seat. ( S. 146)
Page 157: Changing Fuses Of Individual Power Consumers

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. 700281-01 700282-01 – Switch off all power-consuming components and switch off the engine. –...
Page 158

MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove defective fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system (optional) Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp Fuse 3 - 10A - horn, brake light Fuse 4 - 10A - radiator fan Fuse 5 - 10A - fuel pump Fuse 6 - 10A - ignition / fuel injection...
Page 159: Changing The Low Beam Bulb

S. 213) Fuse (75011088015) ( S. 213) Info If the new fuse burns out, contact an authorized KTM-RC8 workshop. Replace the spare fuse in the fuse box so that it is available if needed. – Close the fuse box cover. –...
Page 160

MAINTENANCE WORK ON CHASSIS AND ENGINE 700293-01 700294-01 700295-01 – Fold up the combination instrument. Pull the lug – Remove the rubber holder. – Release the latch  – Remove the lamp cover  – Disconnect plug-in connector  – Push off the retaining clamp ...
Page 161

MAINTENANCE WORK ON CHASSIS AND ENGINE 700296-01 400422-10 – 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 – Position the retaining clamp. –...
Page 162: Change The High Beam Bulb

MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
Page 163

MAINTENANCE WORK ON CHASSIS AND ENGINE 700297-01 700298-01 – Remove screws . Remove cover.  – Release the latch  – Remove the lamp cover ...
Page 164

MAINTENANCE WORK ON CHASSIS AND ENGINE 700299-01 – 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.
Page 165

MAINTENANCE WORK ON CHASSIS AND ENGINE 400422-11 700335-10 – Position the lug of the lamp cover in the notch. Engage the latch.  – Check lighting function. – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. –...
Page 166: Changing The Parking Light Bulb

MAINTENANCE WORK ON CHASSIS AND ENGINE 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.
Page 167

MAINTENANCE WORK ON CHASSIS AND ENGINE 700298-01 700300-01 – 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. Parking light (W2,1x9,5d) ( S.
Page 168

MAINTENANCE WORK ON CHASSIS AND ENGINE 400422-12 700335-11 – Position the lug of the lamp cover in the notch. Engage the latch.  – Check lighting function. – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. –...
Page 169: Checking Headlight Adjustment, Adjusting Headlamp Range

– Make another mark at a distance of  Guideline Distance  – Stand the motorcycle at distance  the low beam. Guideline Distance  – Check the headlight adjustment. The border between light and dark must be exactly at mark ...
Page 170: Activating/deactivating Ignition Key

MAINTENANCE WORK ON CHASSIS AND ENGINE 700285-01 Activating/deactivating ignition key 9.65 Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or replaced, the black ignition keys must be activated/deactivated using the orange programming key. You can activate or deactivate up to four black ignition keys.
Page 171

MAINTENANCE WORK ON CHASSIS AND ENGINE – 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.
Page 172

MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 according to the number of functioning black ignition keys including the orange programming key.
Page 173: Cooling System

MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system 9.66 400415-10 – 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 ...
Page 174: 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. Allow the engine and cool- ing system to cool down.
Page 175: Filling The Cooling System Compensating Tank

9.68 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. Allow the engine and cool- ing system to cool down.
Page 176

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 fail- ure.
Page 177: Adjusting Basic Position Of Clutch Lever, Checking Fluid Level Of Hydraulic Clutch

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.69 700283-01 Checking fluid level of hydraulic clutch 9.70 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw ...
Page 178: Correcting Fluid Level Of Hydraulic Clutch

MAINTENANCE WORK ON CHASSIS AND ENGINE 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. 700284-01 – Check the fluid level. The fluid level must be between the MIN and MAX markings. »...
Page 179

Handlebar height 9.73 700319-12 – 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 ...
Page 180: Adjusting Handlebar Height

MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar height 9.74 Info The handlebar stub position must be identical on the left and the right of the vehicle. 700318-01 700319-01 – Loosen screw  Info Loosen the screw several turns to prevent damaging the fork lacquer when mov- ing the handlebar stub.
Page 181: Rear Frame Position

MAINTENANCE WORK ON CHASSIS AND ENGINE 700320-01 Rear frame position 9.75 400439-10 – 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. »...
Page 182: Adjusting Rear Frame Position

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. 700327-10 700329-01 Setting a higher seat position:...
Page 183

MAINTENANCE WORK ON CHASSIS AND ENGINE 700327-11 700330-01 – 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.
Page 184

MAINTENANCE WORK ON CHASSIS AND ENGINE 700338-01 700327-12 – When you screw in the rear left fixing screw, the plug-in cable binder 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.
Page 185

MAINTENANCE WORK ON CHASSIS AND ENGINE 700327-14 700329-01 700327-13 – 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.
Page 186: Checking Engine Oil Level

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. – Stand the motorcycle upright on a horizontal surface. is pushed ...
Page 187: Changing Engine Oil And Filter, Cleaning Oil Screen

MAINTENANCE WORK ON CHASSIS AND ENGINE 700301-10 Changing engine oil and filter, cleaning oil screen 9.78 700349-01 Draining engine oil, cleaning oil screens 9.79 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –...
Page 188

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 –...
Page 189

MAINTENANCE WORK ON CHASSIS AND ENGINE 700287-01 700292-01 700288-01 – 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.
Page 190

MAINTENANCE WORK ON CHASSIS AND ENGINE 700302-10 Removing oil filter 9.80 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. –...
Page 191

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. 700289-01 700290-01 – Place a suitable container under the engine. – Remove screws ...
Page 192

MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting oil filter 9.81 700291-01 Filling up with engine oil 9.82 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 700301-01 – Insert the oil filter  –...
Page 193

MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the dipstick and top up the engine oil.  Engine oil (1st 3.00 l (3.17 qt.) quantity) – Replace the oil dipstick  Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
Page 194: Topping Up Engine Oil

MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 700301-01 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. –...
Page 195

MAINTENANCE WORK ON CHASSIS AND ENGINE – 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.
Page 196: Troubleshooting

Check the safety start system. – Change the fuses of individual power consumers. ( S. 155) – Join coupling of fuel hose connection together. – Clean plug connector and treat with con- tact spray. – Read the fault memory with KTM DIA. ...
Page 197

– Add suitable fuel. – Change the air filter. – Chang the fuel filter. – Read the fault memory with KTM DIA. – Check the cooling system for leaks. – Check the coolant level. ( S. 172) – Clean cooling fins.
Page 198

TROUBLESHOOTING Faults Brake light and horn do not work Battery discharged Combination instrument shows nothing in display Speedometer in combination instrument doesn't work Possible cause Fuse 3 blown Ignition not switched off when vehicle parked Battery is not charged by the generator Fuse 1 blown Wiring harness of wheel reveolution counter damaged or plug-in connector...
Page 199: Immobilizer Flash Code

IMMOBILIZER FLASH CODE IMMOBILIZER FLASH CODE Fault Description Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Immobilizer indicator lamp flashes 1x short, 1 second pause, 4x short Immobilizer indicator lamp flashes 1x short, 1 second pause, 5x short...
Page 200: Engine Control Flash Code

ENGINE CONTROL FLASH CODE ENGINE CONTROL FLASH CODE Fault Description EFI Warning lamp (MIL) flashes 2x short EFI Warning lamp (MIL) flashes 6x short EFI Warning lamp (MIL) flashes 7x short EFI Warning lamp (MIL) flashes 9x short EFI Warning lamp (MIL) flashes 1x long, 1x short EFI Warning lamp (MIL) flashes 1x long, 3x short Possible cause Action...
Page 201

ENGINE CONTROL FLASH CODE Fault Description EFI Warning lamp (MIL) flashes 1x long, 3x short EFI Warning lamp (MIL) flashes 1x long, 4x short EFI Warning lamp (MIL) flashes 1x long, 5x short EFI Warning lamp (MIL) flashes 1x long, 7x short EFI Warning lamp (MIL) flashes 1x long, 8x short EFI Warning lamp (MIL) flashes 2x long, 4x short EFI Warning lamp (MIL) flashes...
Page 202

ENGINE CONTROL FLASH CODE Fault Description EFI Warning lamp (MIL) flashes 4x long, 1x short EFI Warning lamp (MIL) flashes 4x long, 5x short EFI Warning lamp (MIL) flashes 4x long, 6x short EFI Warning lamp (MIL) flashes 4x long, 9x short EFI Warning lamp (MIL) flashes 5x long EFI Warning lamp (MIL) flashes 5x long, 4x short EFI Warning lamp (MIL) flashes 6x long, 1x short...
Page 203

ENGINE CONTROL FLASH CODE Fault Description EFI Warning lamp (MIL) flashes 6x long, 2x short EFI Warning lamp (MIL) flashes 6x long, 8x short EFI Warning lamp (MIL) flashes 6x long, 9x short EFI Warning lamp (MIL) flashes 7x long, 2x short EFI Warning lamp (MIL) flashes 9x long, 1x short Possible cause Action –...
Page 204: Cleaning, Cleaning Motorcycle

If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt. – After cleaning the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
Page 205

CLEANING 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.
Page 206: Conservation 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 207: Storage, Storage

(less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. – Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation. – Clean the motorcycle. ( S.
Page 208: Putting Into Operation After Storage

Putting into operation after storage 15.2 – Take the front of the motorcycle off the work stand. ( – Take the rear of the motorcycle off the work stand. ( –...
Page 209: Technical Data - Engine

TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design Displacement Stroke Bore Compression ratio Control Valve - diameter Intake Exhaust Valve clearance Exhaust at: 20 °C (68 °F) Intake at: 20 °C (68 °F) Crankshaft bearing Conrod bearing Piston pin bearing Piston Piston ring Engine lubrication Primary transmission Clutch...
Page 210: Capacity - Engine Oil, Capacity - Coolant

TECHNICAL DATA - ENGINE 3rd gear 4th gear 5th gear 6th gear Mixture preparation Ignition system Generator Spark plug Electrode gap, spark plug Cooling Cold start device Capacity - engine oil 16.1 Engine oil 3.60 l (3.8 qt.) Capacity - coolant 16.2 Coolant 2.60 l (2.75 qt.) 20:30...
Page 211: Technical Data - Engine Tightening Torques

TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES Hose clip, intake flange Screw, gear sensor Screw, pulse generator Screw, bearing retainer Remaining engine screws Oil jet Nut, cylinder head Screw, locking lever Screw, freewheel holder Screw, freewheel ring Screw, generator cover Stud, chain shaft Screw, coolant connection on cylinder...
Page 212

TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, stator clamp Plug, vacuum connection Screw, valve cover Screw, water pump cover Screw, water pump wheel Remaining engine screws Vacuum connection Stud, exhaust flange Screw, timing chain guide rail Plug, crankshaft retainer Screw, engine housing Screw, engine console Screw, camshaft bearing support Screw, camshaft bearing support...
Page 213

TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, conrod bearing Plug, cam lever axis Screw, cylinder head Coolant temperature sensor Screw, ignition rotor Spark plug Oil drain plug Nut, inner clutch hub Screw in generator cover Plug, timing-chain tensioner Nut, primary gear M10x1 Step 1 25 Nm (18.4 lbf ft)
Page 214: Technical Data - Chassis

TECHNICAL DATA - CHASSIS TECHNICAL DATA - CHASSIS Frame Fork Shock absorber Suspension travel front rear Brake system front rear Brake discs - diameter front rear Brake discs - wear limit front rear Tire air pressure, Solo front rear Tire air pressure with passenger / full payload front rear Secondary drive...
Page 215: Lighting Equipment

TECHNICAL DATA - CHASSIS Chain Steering head angle Wheelbase Seat height, unloaded Lower frame rear position Upper frame rear position Ground clearance, unloaded Weight without fuel Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible total weight Battery Fuse Fuse...
Page 216: Capacity - Fuel

TECHNICAL DATA - CHASSIS Brake/tail light License plate lamp Front tire 120/70 ZR 17 58 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 16.5 l (4.36 US gal) Fuel reserve W2,1x9,5d Rear tire 190/55 ZR 17 75 W TL Pirelli Dragon Supercorsa Pro Super unleaded (ROZ 95 / RON 95 / PON 91) ( 3.5 l (3.7 qt.)
Page 217: Technical Data - Fork

TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number Fork Compression damping Comfort Standard Sport full payload Rebound damping Comfort Standard Sport Full payload Spring preload - Preload Adjuster Comfort Standard Sport full payload Spring length with preload spacer(s) Spring rate Weight of rider: 75…...
Page 218: Technical Data - Shock Absorber

TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number Shock absorber Compression damping, high-speed Comfort Standard Sport full payload Compression damping, low-speed Comfort Standard Sport full payload Rebound damping Comfort Standard Sport full payload Spring preload Comfort Standard Sport...
Page 219

TECHNICAL DATA - SHOCK ABSORBER Spring length Gas pressure Static sag Riding sag Inbuilt length 160 mm (6.3 in) 10 bar (145 psi) 15 mm (0.59 in) 30 mm (1.18 in) 290 mm (11.42 in)
Page 220: Technical Data - Chassis Tightening Torques

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, side stand switch Screw, brake fluid reservoir of rear brake Screw, brake line holder Screw, chain sliding piece Screw, chain guard Screw, fuel level indicator Screw, steering damper fixing bracket Remaining chassis screws Remaining chassis nuts Screw, exhaust heat shield...
Page 221

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, front brake disc Screw, spring holder on side stand bracket Screw, rear footrest bracket Screw, front footrest bracket Screw, top triple clamp Screw, bottom triple clamp Screw, fork stub Screw, steering stem Screw, handlebar stub Screw, steering damper fixing bracket Screw, steering damper clamp on con- sole...
Page 222

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, connecting lever, shock absorber deflector Remaining chassis screws Nut, deflection lever on frame Lambda probe Nut, swingarm pivot Screw, seat lock Nut, rear wheel spindle Screw, front wheel spindle Screw, steering head 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft) M14x1.5 100 Nm (73.8 lbf ft)
Page 223: Substances

SUBSTANCES Brake fluid DOT 4 / DOT 5.1 according to – Specification – 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 Suppler Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ® Motorex –...
Page 224

SAE ( 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 fully synthetic engine oil Suppler ® Motorex –...
Page 225

– ISO VG (15) Specification – 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 Suppler ® Motorex – Hydraulic Fluid 75 Super unleaded (ROZ 95 / RON 95 / PON 91) according to –...
Page 226: Auxiliary Substances

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. Suppler ® Motorex – Fett 2000...
Page 227

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. Suppler ®...
Page 228: Standards

Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements.
Page 229: Index

INDEX INDEX Battery fitting ........150 recharging .
Page 230

INDEX Electric starter button ......23 Emergency OFF switch ......22 Engine running in .
Page 231

Maximum speed displaying ........61 Motorcycle cleaning .
Page 232

INDEX Parking ........88 Parking light bulb changing .
Page 233

INDEX Shock absorber part number ......18 Side stand ........76 Spare parts, accessories .
Page 234

*3211250en* 3211250en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 02/2008 Photo Mitterbauer...

Authorisation

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