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OWNER'S MANUAL 2010 1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR 1190 RC8 R JP Art. no. 3211525en...
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KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Reproduction, even in part, as well as copying of all kinds, 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.
TABLE OF CONTENTS Notes/warnings on the combination instrument....30 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Overview of ROAD mode............ 34 IMPORTANT INFORMATION ........... 8 Odometer menu ODO/Trip 1 ..........35 VIEW OF VEHICLE..............12 Odometer menu ODO/Trip 2 ..........36 View of vehicle, front left side..........
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TABLE OF CONTENTS Displaying maximum speed ..........67 Braking ................93 Setting ROAD or RACE mode..........68 Stopping, parking ............. 94 Setting the clock with SET CLOCK ........68 Refueling................. 95 Adjusting shift speed RPM1/2 ........... 69 SERVICE SCHEDULE............97 Setting the blank time of the LAP button LAP BLANK T..
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TABLE OF CONTENTS Adjusting shift lever stub..........120 Removing the passenger seat........... 154 Adjusting shift lever............120 Mounting the passenger seat ........... 154 Adjusting the foot brake lever stub ........124 Mounting the helmet lock on the vehicle......155 Adjusting the foot brake lever .......... 125 Removing the battery ..........
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TABLE OF CONTENTS Removing the oil filter ..........199 Installing the oil filter ..........201 Filling up with engine oil ..........201 Adding engine oil ............203 TROUBLESHOOTING............205 IMMOBILIZER BLINK CODE..........208 ENGINE CONTROL BLINK CODE ......... 210 CLEANING................. 216 Cleaning motorcycle ............
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.
IMPORTANT INFORMATION 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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IMPORTANT INFORMATION 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.
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IMPORTANT INFORMATION 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.
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IMPORTANT INFORMATION 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.
VIEW OF VEHICLE View of vehicle, front left side 100652-10...
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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...
VIEW OF VEHICLE View of vehicle, rear right side 100653-10...
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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 lever Engine number Brake calipers, front...
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.
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...
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.
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.
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 –...
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 –...
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 –...
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.
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.
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.
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. ...
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.
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.
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.
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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.
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CONTROLS 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 ICE appears on the info display if the external temperature falls below the specified value. Temperature 3 °C (37 °F) ICE disappears if the external temperature rises above the specified value.
CONTROLS Functions in ROAD mode Odometer menu ODO/Trip 1 Odometer menu ODO/Trip 2 FUELDISTANCE menu FUELRANGE menu DISTANCE TO Next Service menu Odometer menu ODO/Trip 1 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.
CONTROLS Press the MODE but- The display of Trip 1, Time 1 and Avs 1 is reset ton for 3 - 5 sec- onds. Press the MODE but- Next display mode ton briefly. Odometer menu ODO/Trip 2 5.20 Condition • The ignition is on.
CONTROLS Press the MODE but- Next display mode ton briefly. FUELDISTANCE menu 5.21 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.
CONTROLS FUELRANGE menu 5.22 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.
CONTROLS DISTANCE TO Next Service menu 5.23 Condition • The ignition is on. • The motorcycle is stationary. • 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...
CONTROLS Functions in RACE mode LAPSTOGO menu TOPSPEED menu Lap time LAP/BESTLAP/LastLap menu Top speed LAP/BESTLAP/TopSpeed menu Total distance in Race Mode RACEODO menu LAPSTOGO menu 5.25 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.
CONTROLS Press the MODE but- All values in RACE mode are reset (except RACEODO) ton for 3 - 5 sec- onds. Press the MODE but- Next display mode ton briefly. TOPSPEED menu 5.26 Condition • The ignition is on. • RACE Mode –...
CONTROLS Press the MODE but- The display of LastLap, ±Last and ±Best are set to 0 ton for 3 - 5 sec- onds. Press the MODE but- Next display mode ton briefly. LAP/BESTLAP/LastLap menu 5.27 Condition • The ignition is on. •...
CONTROLS Press the MODE but- Next display mode ton briefly. LAP/BESTLAP/TopSpeed menu 5.28 Condition • The ignition is on. • The motorcycle is stationary. • RACE Mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in the info display. LAP shows the selected lap.
CONTROLS Total distance menu in Race mode RACEODO 5.29 Condition • The ignition is on. • The motorcycle is stationary. • 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.
CONTROLS SET‑UP menu 5.31 Condition • The ignition is on. • The motorcycle is stationary. – 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.
CONTROLS CHANGE MODE menu 5.32 Condition • The ignition is on. • The motorcycle is stationary. – 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...
CONTROLS SET CLOCK menu 5.33 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button once until the symbol shows SET CLOCK in the info display. –...
CONTROLS SETTINGS menu 5.34 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS SHIFT RPMS menu 5.35 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS LAP menu, LAP BLANK T button 5.36 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS SET NUM LAPS menu 5.37 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS TRIP F RESET menu 5.38 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS UNITS menu 5.39 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
CONTROLS SET KM/MILES menu 5.40 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
CONTROLS SET °C/°F menu 5.41 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
CONTROLS OPTIONS menu 5.42 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
CONTROLS TPMS menu 5.43 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
CONTROLS OUTERTEMP menu 5.44 Condition • The ignition is on. • The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. –...
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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...
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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/ The next lap is dis- The previous lap is The display All values in...
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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...
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CONTROLS Table of conditions and menu activation 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. •...
CONTROLS Table of conditions and menu activation 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. •...
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. –...
CONTROLS Setting ROAD or RACE mode 5.47 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the MODE button briefly. The mode set is shown in the info display. –...
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 5.49 Condition...
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 –...
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CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display. – Press the MODE button briefly. – shows LAP BLANK T in the info display. Press the button once until the symbol –...
CONTROLS Setting the number of laps SET NUM LAPS 5.51 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS Setting the fuel reserve display TRIPF RESET 5.52 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol appears in front of SETTINGS in the info display.
CONTROLS – Press the MODE button briefly. Setting the kilometers/miles SET KM/MILES 5.53 Info Making a country-specific setting. Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display.
CONTROLS Setting the temperature unit SET °C/°F 5.54 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. –...
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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.
CONTROLS Opening the filler cap 5.56 – Lift the cover of the filler cap and insert the ignition key in the lock. Note Danger of damage Ignition key breakage. – To take pressure off of the ignition key, push down on the filler cap. Damaged igni- tion keys must be replaced.
CONTROLS Closing the filler cap 5.57 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.
CONTROLS Seat lock 5.59 The seat lock is behind the seat. It can be locked with the ignition key. 100669-10 Tool set 5.60 The tool set is in the storage compartment under the seat. 100670-10...
CONTROLS Helmet lock 5.61 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.
CONTROLS Shift lever 5.63 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...
CONTROLS Foot brake lever 5.64 The foot brake lever is in front of the right footrest. The foot brake lever operates the rear brake. 100675-10 Side stand 5.65 The side stand is coupled with the safety start system; see the riding instructions. ...
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 characteristic 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. –...
TIPS ON PUTTING INTO OPERATION – 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. – Before your first trip, read the entire operating instructions carefully.
TIPS ON PUTTING INTO OPERATION Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – 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.
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. –...
RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch on 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.
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 change down at high engine speed, the rear wheel can lock up. –...
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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. –...
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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.
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 Failure of brake system. –...
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. –...
RIDING INSTRUCTIONS – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. –...
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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.
Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • • Change the engine oil and filter, clean the oil screen. p. 195) • •...
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SERVICE SCHEDULE K10N K100A K200A K400A Bleed fork legs. ( p. 105) • • • Check the steering head bearing play. • • • • Change the spark plugs. • • • • Check the valve clearance. Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and •...
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• • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • Make the service entry in KTM DEALER.NET and in the service record. K10N: Once after 1,000 km (621.4 mi)
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle front Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle at the rear. ( p.
MAINTENANCE WORK ON FRAME AND ENGINE Jacking up motorcycle at the rear Note Danger of damage The parked vehicle may 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) –...
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 .
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...
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...
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...
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.)
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.)
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.)
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...
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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.
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.
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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…...
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.
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. –...
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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. –...
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. –...
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 controls.
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MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws 100713-10 – Position the footrest bracket with spacers and screws. Guideline Standard Upper position Info The adjustable footrest bracket enables a more comfortable lower footrest posi- tion or a sporting upper footrest position. 100700-10 –...
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MAINTENANCE WORK ON FRAME AND ENGINE – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( p. 120) – Adjust the foot brake lever. ( p. 125) 100702-01...
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...
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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) –...
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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,...
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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 ...
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the foot brake lever stub 9.24 – Remove the screw with the foot brake lever stub. – Position the foot brake lever stub with the screw in one of the holes according to the ...
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the foot brake lever 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.
MAINTENANCE WORK ON FRAME AND ENGINE – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3…...
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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. Warning Environmental hazard Hazardous substances cause environmental damage.
MAINTENANCE WORK ON FRAME AND ENGINE Checking 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.
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the chain tension 9.30 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.
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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 ...
MAINTENANCE WORK ON FRAME AND ENGINE Checking the chain, rear sprocket and engine sprocket 9.31 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together.
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MAINTENANCE WORK ON FRAME AND ENGINE – Shift into neutral, and pull the lower chain section with the specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. ...
10 Nm (7.4 lbf ft) 100710-10 Checking the front brake discs 9.32 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.)
– Change the brake discs. Checking the rear brake disc 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.)
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. ...
Warning Danger of accidents Reduced braking effect caused by 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.
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Warning Danger of accidents Reduced braking effect caused by 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.
Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.37 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 from accessory suppliers are often not tested and approved for use on KTM vehicles.
(Your authorized KTM RC8 workshop will be pleased to help.) Warning Danger of accidents Reduced braking effect caused by 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.)
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. – 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.)
Clean up overflowed or spilt brake fluid immediately with water. 100717-10 Checking the rear brake linings 9.41 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.)
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.
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MAINTENANCE WORK ON FRAME AND ENGINE – Loosen screws – Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs.
MAINTENANCE WORK ON FRAME AND ENGINE Installing the front wheel 9.43 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.
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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. –...
MAINTENANCE WORK ON FRAME AND ENGINE – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Fully tighten screws Guideline Fork end pinch bolts 15 Nm (11.1 lbf ft) 100782-10 Removing the rear wheel 9.44 –...
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 efficiency caused by damaged brake discs. – Always lay the wheel down in such a way that the brake discs are not dam- aged.
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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. 239) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: –...
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MAINTENANCE WORK ON FRAME AND ENGINE – Push the rear wheel as far forward as possible and place the chain on the rear sprocket. – Pull the rear wheel back and insert the axle. 100726-01 – Place the chain adjuster on the tensioning screw.
MAINTENANCE WORK ON FRAME AND ENGINE Checking rear hub cush drive 9.46 Info The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out dur- ing operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged. –...
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MAINTENANCE WORK ON FRAME AND ENGINE Warning Danger of accidents Uncontrollable handling characteristic 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. –...
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.
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 9.49 – Insert the ignition key in the seat lock and turn it clockwise.
MAINTENANCE WORK ON FRAME AND ENGINE Removing the passenger seat 9.51 – Remove the seat. ( p. 153) – Activate the release lever – Take off the passenger seat toward the top. 100731-10 Mounting the passenger seat 9.52 Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.
MAINTENANCE WORK ON FRAME AND ENGINE Mounting the helmet lock on the vehicle 9.53 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.
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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. –...
MAINTENANCE WORK ON FRAME AND ENGINE – Remove screws – Removing the securing bracket – Pull the battery up and out of the battery rack. 100736-10 Installing the battery 9.55 – Position the battery in the battery rack. Info The terminals of the battery must face the rear of the vehicle.
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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 cover of the positive terminal. 100738-10 – Reconnect the negative (minus) cable of 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.
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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.
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 alternator. With this device, you cannot overcharge the battery. Info Never remove lid ...
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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. 153) –...
MAINTENANCE WORK ON FRAME AND ENGINE Changing the fuses of individual power consumers 9.58 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.
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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...
MAINTENANCE WORK ON FRAME AND ENGINE – Close the fuse box cover. – Fit the seat. ( p. 153) Changing the low beam bulb 9.59 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
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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 ...
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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.
MAINTENANCE WORK ON FRAME AND ENGINE Changing the high beam bulb 9.60 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
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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.
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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. 400422-11 – Position the cover. Info Check for correct positioning and freedom of movement of the brake lines. –...
MAINTENANCE WORK ON FRAME AND ENGINE Changing the parking light bulb 9.61 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
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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. 227) – Carefully position the holder with the bulb in the holder in the headlight.
MAINTENANCE WORK ON FRAME AND ENGINE – Position the 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 headlight setting 9.62 –...
MAINTENANCE WORK ON FRAME AND ENGINE » If the boundary between light and dark does not meet specifications: – Adjust the headlamp range. ( p. 174) Adjusting the headlamp range 9.63 – Check the headlight setting. ( p. 173) – Turn the screw to adjust the headlight range.
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MAINTENANCE WORK ON FRAME AND ENGINE Loss of a black ignition key (second black ignition key available): If a black ignition key is lost or replaced, the black ignition keys must be individually activated/deactivated using the orange programming key. This will also prevent the vehi- cle from being operated without authorization with the lost black ignition key.
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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. The lost black ignition key is deactivated. 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.
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MAINTENANCE WORK ON FRAME AND ENGINE programmed during the activation procedure are invalid, but can be reprogrammed in a further activation procedure. – Press the emergency OFF switch into the position – Insert the orange programming key in the ignition lock. –...
MAINTENANCE WORK ON FRAME AND ENGINE All black ignition keys are activated included in this job sequence are activated. Cooling system 9.65 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.
MAINTENANCE WORK ON FRAME AND ENGINE Checking the coolant level 9.66 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
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.)
MAINTENANCE WORK ON FRAME AND ENGINE Alternative 2 Coolant (mixed ready to use) ( p. 235) – Mount the cap of the compensating tank. Adjusting basic position of clutch lever 9.68 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw ...
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.
MAINTENANCE WORK ON FRAME AND ENGINE Checking the play in the throttle cable 9.71 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...
– Move the handlebar to the straight-ahead position. – Throttle position sensor circuit A - check in zero position. Info It is imperative to use the KTM diagnostics tool for this. – Push back protective cover – Loosen lock nut ...
MAINTENANCE WORK ON FRAME AND ENGINE Handlebar position The handlebar stubs can be set to two different positions, enabling ergonomic adjustment of the handlebar position. Handlebar position difference 6.5° between Standard Position 600925-10 Adjusting the handlebar height/position 9.74 Info The handlebar stub position must be identical on the left and right of the vehicle.
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MAINTENANCE WORK ON FRAME AND ENGINE – Remove distance sleeve – All cables routed under the upper triple clamp must now be routed under the han- dlebar stub. – Push the handlebar stub carefully up to the upper triple clamp. Watch out for the handlebar position difference.
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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 paint when moving the handlebar stub. 100759-10 – Remove screw with distance sleeve ...
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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. »...
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MAINTENANCE WORK ON FRAME AND ENGINE – Position the distance sleeve. – Mount and tighten screw Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) – Tighten screw Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) 600986-10 –...
MAINTENANCE WORK ON FRAME AND ENGINE Adjusting the rear frame position 9.76 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. –...
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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. ...
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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.
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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 ...
MAINTENANCE WORK ON FRAME AND ENGINE Checking the engine oil level 9.77 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. ...
MAINTENANCE WORK ON FRAME AND ENGINE Draining the engine oil and cleaning the oil screens 9.79 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
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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 level surface. – Place a suitable container under the engine. – Remove oil drain plug with the magnet, O-rings and oil screen.
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MAINTENANCE WORK ON FRAME AND ENGINE – Thoroughly clean 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)
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 9.80 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –...
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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 .
MAINTENANCE WORK ON FRAME AND ENGINE Installing the oil filter 9.81 – 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...
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MAINTENANCE WORK ON FRAME AND ENGINE Engine oil (1st 3.00 l (3.17 qt.) External Engine oil (SAE quantity) temperature: 5W/40) ( p. 236) < 0 °C (< 32 °F) – Replace the oil dipstick Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
MAINTENANCE WORK ON FRAME AND ENGINE – Start the engine and check that it is oil-tight. – Check the engine oil level. ( p. 195) Adding engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –...
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MAINTENANCE WORK ON FRAME AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
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 the immobilizer blink code. – EFI control unit not activated Encode the EFI control unit.
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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. –...
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TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 195) – Engine oil too thin (viscosity) Change the engine oil and filter, clean the oil screen. p. 195) –...
IMMOBILIZER BLINK CODE Blink 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 Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition ICU antenna malfunction Blink code of immobilizer indica-...
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IMMOBILIZER BLINK CODE Blink 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 Blink 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 Blink code of immobilizer indica-...
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.
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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.
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. –...
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 at the rear. ( p. 101) –...
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 –...
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...
TECHNICAL DATA - CHASSIS 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...
TECHNICAL DATA - CHASSIS 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.)
120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Pirelli Diabolo Supercorsa SP Pirelli Diabolo Supercorsa SP 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.
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...
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...
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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. 237) SAE 2,5...
– 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 ®...
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SAE ( p. 241) (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 –...
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– 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...
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SUBSTANCES Super unleaded (ROZ 98 / RON 98 / PON 94) According to – DIN EN 228 (ROZ 98 / RON 98 / PON 94)
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.
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