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1190 RC8 JP 2008
KTM 1190 RC8 JP 2008 Manuals
Manuals and User Guides for KTM 1190 RC8 JP 2008. We have
2
KTM 1190 RC8 JP 2008 manuals available for free PDF download: Repair Manual, Setup Instructions
KTM 1190 RC8 JP 2008 Repair Manual (210 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 9.1 MB
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Location of Serial Numbers
9
Chassis Number/Type Label
9
Key Number
9
Engine Number
9
Fork Part Number
9
Shock Absorber Part Number
9
Steering Damper Part Number
10
Motorcycle
11
Jacking up Motorcycle Front
11
Taking Front of Motorcycle off Work Stand
11
Jacking up Motorcycle Rear
11
Taking Rear of Motorcycle off Work Stand
11
Starting
12
01/Fork, Triple Clamp
13
Adjusting Compression Damping of Fork
13
Adjusting Rebound Damping of Fork
13
Adjusting Spring Preload of Fork
14
Bleeding Fork Legs
14
Vehicle Level
15
Adjusting Front Vehicle Level
15
02/Handlebar, Controls and Instruments
17
Adjusting Basic Position of Clutch Lever
17
Adjusting the Steering Damper
17
Adjusting the Handlebar Height
17
Adjusting Gas Bowden Cable
18
03/Frame
19
Footrest Position
19
Adjusting Footrest Position
19
Rear Frame Position
20
Adjusting the Rear Frame Position
20
04/Shock Absorber, Swingarm
23
Adjusting the Low-Speed Compression Damping of the Shock Absorber
23
Adjusting High-Speed Compression Damping of the Shock Absorber
23
Adjusting Rebound Damping of the Shock Absorber
24
Adjusting Spring Preload of Shock Absorber
24
Adjusting the Vehicle Level at the Rear
25
05/Exhaust
26
Removing the Exhaust Cover Completely
26
Installing the Exhaust Cover Completely
26
Removing the Exhaust System
26
Installing the Exhaust System
28
06/Air Filter
30
Removing the Air Filter
30
Installing the Air Filter
30
Removing the Filter Box Bottom
30
Installing the Filter Box Bottom
32
07/Fuel Tank, Seat, Trim
34
Removing the Seat
34
Fitting the Seat
34
Removing Passenger Seat
34
Fitting the Passenger Seat
34
Dismounting the Fuel Tank
34
Installing the Fuel Tank
35
Removing the Fuel Tank Guard
36
Installing the Fuel Tank Guard
37
08/Mask, Fender, Decal
38
Removing the Side Covers
38
Installing the Side Covers
38
Removing the Inside Cover
38
Installing the Inside Cover
39
09/Front Wheel
40
Removing Front Wheel
40
Fitting Front Wheel
40
Tire Condition Checking
41
Checking Tire Air Pressure
41
Checking the Front Brake Discs
42
10/Rear Wheel
43
Removing Rear Wheel
43
Installing the Rear Wheel
43
Installing the Rear Wheel - When Installing the Engine
44
Tire Condition Checking
46
Checking Tire Air Pressure
46
Checking the Rear Brake Disc
47
Checking for Chain Dirt
47
Cleaning the Chain
47
Checking the Chain Tension
47
Adjusting the Chain Tension
48
Checking Rear Sprocket / Engine Sprocket for Wear
49
Checking Chain Wear
49
Checking Chain Sliding Guard
49
Checking Rear Hub Shock Absorbers
49
11/Wiring Harness, Battery
51
Removing the Battery
51
Installing the Battery
51
Recharging the Battery
52
Changing the Main Fuse
53
Changing the Fuses of Individual Power Consumers
54
13/Brake System
55
Brake Linings
55
Checking the Front Brake Linings
55
Checking Brake Fluid Level of Front Brake
55
Topping up Brake Fluid of Front Brake
56
Adjusting the Basic Position of the Handbrake Lever
56
Checking the Rear Brake Linings
56
Checking Rear Brake Fluid Level
57
Topping up Rear Brake Fluid
57
Adjusting the Footbrake Pedal Stub
58
Adjusting the Footbrake Pedal
58
Removing the Rear Brake System
59
Installing the Rear Brake System
59
14/Light System, Instruments
60
Activating/Deactivating Ignition Key
60
Setting ROAD or RACE Mode
61
Setting the Clock with SET CLOCK
62
Adjusting Shift Speed RPM1/2
62
Setting the Blank Time of the LAP Button LAP BLANK T
63
Setting Number of Laps SET NUM LAPS
63
Setting Fuel Reserve Display TRIPF RESET
64
Setting Kilometers/Miles SET KM/MILES
64
Setting Temperature Unit SET °C/°F
65
Switching External Temperature Display On/Off
65
Resetting the Service Display
65
Checking Headlight Adjustment
66
Adjusting Headlamp Range
66
Changing the Parking Light Bulb
67
Changing the Low Beam Bulb
68
Change the High Beam Bulb
69
30/Engine
72
Removing the Engine
72
Preparing the Engine for Installation
74
Installing the Engine
74
Setting the Engine to Ignition Top Dead Center of the Rear Cylinder
78
Setting the Engine to Ignition Top Dead Center of the Front Cylinder
78
30/Disassembling the Engine
79
Clamping the Engine into the Engine Work Stand
79
Draining the Engine Oil
79
Removing the Front Valve Cover
79
Removing the Rear Valve Cover
79
Setting the Engine to Ignition Top Dead Center of the Rear Cylinder
80
Removing the Starter Motor
80
Removing the Oil Filler Tube
80
Removing the Heat Exchanger
81
Removing the Rear Timing Chain Tensioner
81
Removing the Rear Camshaft
81
Removing the Rear Cylinder Head
82
Removing the Rear Piston
82
Setting the Engine to Ignition Top Dead Center of the Front Cylinder
82
Removing the Front Timing Chain Tensioner
82
Removing the Front Camshafts
83
Removing the Front Cylinder Head
83
Removing the Front Piston
83
Removing the Generator Cover
84
Removing the Ignition Pulse Generator
84
Removing the Torque Limiter and Idler
84
Removing the Rotor
84
Removing the Idler and Timing Chain on the Left
85
Removing the Oil Filter
86
Removing the Balancer Shaft
86
Removing the Drive Wheel of the Balancer Shaft
86
Removing the Gear Position Sensor
86
Removing the Left Suction Pump
87
Removing the Water Pump Wheel
88
Removing the Clutch Cover
88
Removing the Idler and Timing Chain on the Right
88
Removing the Clutch Facing
89
Removing the Outer Clutch Hub
89
Removing the Primary Gear
90
Removing the Force Pump
90
Removing the Shift Shaft
91
Removing the Shift Drum Locating
91
Removing the Locking Lever
91
Removing the Left Engine Case
92
Removing the Crankshaft
92
Removing the Middle Suction Pump
92
Removing the Transmission Shaft
93
Removing the Oil Spray Tube
94
Removing the Timing Chain Rails of the Right Engine Case Section
94
Removing the Timing Chain Rails of the Left Engine Case Section
94
30/Engine - Work on Individual Parts
95
Work on the Right Section of the Engine Case
95
Removing the Main Bearing of the Right Engine Case Section
96
Selecting the Main Bearing Shells
97
Installing the Right Main Bearing
97
Work on the Left Section of the Engine Case
98
Removing the Left Main Bearing
100
Installing the Left Main Bearing
100
Changing the Conrod Bearing
101
Work on the Clutch Cover
102
Changing the Step Bearing of the Crankshaft
103
Checking the Radial Clearance of the Bottom Connecting Rod Bearing
104
Checking/Measuring the Cylinder
104
Checking/Measuring the Piston
105
Checking the Piston Ring End Gap
106
Checking the Piston/Cylinder Mounting Clearance
106
Work on the Cylinder Head
106
Checking the Cylinder Head
109
Work on the Right Idler
110
Checking the Timing Assembly
111
Preparing the Timing Chain Tensioner for Installation
111
Checking the Oil Pressure Regulator Valve
112
Checking the Oil Pumps
112
Checking the Clutch
113
Checking the Shift Mechanism
114
Preassembling the Shift Shaft
115
Dismantling the Main Shaft
115
Dismantling the Countershaft
116
Checking the Transmission
117
Assembling the Main Shaft
118
Assembling the Countershaft
118
30/Assembling the Engine
120
Installing the Timing Chain Rails of the Left Engine Case Section
120
Installing the Timing Chain Rails of the Right Engine Case Section
120
Installing the Oil Spray Tube
121
Installing the Transmission Shaft
121
Installing the Middle Suction Pump
122
Installing the Crankshaft
122
Installing the Left Engine Case
123
Installing the Locking Lever
124
Installing the Shift Drum Locating
124
Installing the Shift Shaft
124
Installing the Force Pump
125
Installing the Left Suction Pump
126
Setting the Engine to Ignition Top Dead Center of the Rear Cylinder
126
Installing the Primary Gear
127
Installing the Outer Clutch Hub
127
Installing the Clutch Facing
128
Installing the Idler and Timing Chain on the Right
129
Installing the Clutch Cover
129
Installing the Water Pump Wheel
130
Installing the Gear Position Sensor
130
Installing the Drive Wheel of the Balancer Shaft
130
Installing the Balancer Shaft
131
Installing the Idler and Timing Chain on the Left
131
Installing the Oil Filter
132
Installing the Rotor
132
Installing the Torque Limiter and Idler
133
Installing the Ignition Pulse Generator
133
Installing the Generator Cover
133
Installing the Oil Drain Plug
133
Installing the Rear Piston
134
Installing the Rear Cylinder Head
135
Installing the Rear Camshaft
136
Installing the Rear Timing Chain Tensioner
136
Setting the Engine to Ignition Top Dead Center of the Front Cylinder
137
Installing the Front Piston
137
Installing the Front Cylinder Head
139
Installing the Front Camshafts
139
Installing the Front Timing Chain Tensioner
140
Installing the Heat Exchanger
140
Installing the Oil Filler Tube
141
Installing the Starter Motor
141
Checking the Rear Valve Clearance
141
Adjusting the Rear Valve Clearance
142
Checking the Front Valve Clearance
142
Adjusting the Front Valve Clearance
142
Installing the Front Valve Cover
143
Installing the Rear Valve Cover
143
32/Clutch
144
Checking Fluid Level of Hydraulic Clutch
144
Correcting Fluid Level of Hydraulic Clutch
144
34/Shift Mechanism
145
Adjusting Shift Lever Stub
145
Adjusting Shift Lever
145
35/Water Pump, Cooling System
147
Checking the Coolant Level
147
Checking the Antifreeze
147
Removing the Radiator
148
Installing the Radiator
148
Adding Coolant/Bleeding the Cooling System
149
Filling the Cooling System Compensating Tank
150
36/Cylinder Head
151
Checking the Valve Clearance
151
Adjusting the Rear Valve Clearance
152
Adjusting the Front Valve Clearance
152
Removing the Rear Camshaft
153
Installing the Rear Camshaft
153
Removing the Front Camshafts
154
Installing the Front Camshafts
154
Removing the Rear Timing Chain Tensioner
154
Installing the Rear Timing Chain Tensioner
155
Removing the Front Timing Chain Tensioner
155
Installing the Front Timing Chain Tensioner
155
38/Lubrication System
156
Oil Circuit
156
Checking Engine Oil Level
157
Changing Engine Oil and Filter, Cleaning Oil Screen
157
Draining Engine Oil, Cleaning Oil Screens
157
Removing Oil Filter
159
Fitting Oil Filter
160
Filling up with Engine Oil
160
Topping up Engine Oil
161
Immobilizer Flash Code
162
Engine Control Error Code
163
Technical Data - Engine
165
Capacity- Engine Oil
165
Capacity - Coolant
165
Technical Data - Tolerance, Wear Limits of Engine
166
Technical Data - Engine Tightening Torques
168
Technical Data - Chassis
170
Lighting Equipment
171
Capacity - Fuel
171
Technical Data - Fork
172
Technical Data - Shock Absorber
173
Technical Data - Chassis Tightening Torques
174
Cleaning/Conservation
176
Cleaning Motorcycle
176
Conservation for Winter Operation
176
Storage
177
Putting into Operation after Storage
177
Greasing and Service Table
178
Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop
178
Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop. (as Additional Job)
179
Wiring Diagram
180
Of 3
180
Of 3
184
Of 3
190
Substances
194
Auxiliary Substances
196
Special Tools
197
Standards
205
Index
206
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KTM 1190 RC8 JP 2008 Setup Instructions (14 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 0.57 MB
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