KTM 1190 RC8 EU 2008 Repair Manual
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KTM 1190 RC8 EU 2008 Repair Manual

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REPAIR MANUAL
2008
1190 RC8 EU
1190 RC8 AUS/UK
1190 RC8 FR
1190 RC8 JP
Article no. 3206057en

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Summary of Contents for KTM 1190 RC8 EU 2008

  • Page 1 REPAIR MANUAL 2008 1190 RC8 EU 1190 RC8 AUS/UK 1190 RC8 FR 1190 RC8 JP Article no. 3206057en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    CONTENTS Removing the inside cover..........36 CONTENTS MEANS OF REPRESENTATION ..........5 Installing the inside cover ..........37 IMPORTANT NOTES ............6 09/FRONT WHEEL ............38 LOCATION OF SERIAL NUMBERS ........7 Removing front wheel ............ 38 Chassis number/type label ..........7 Fitting front wheel ............
  • Page 5 CONTENTS Preparing the engine for installation ........ 72 Removing the left main bearing ........98 Installing the engine ............72 Installing the left main bearing ........98 Setting the engine to ignition top dead center of the rear Changing the conrod bearing .......... 99 cylinder ................
  • Page 6 KTM-RC8 workshop........176 Adjusting the rear valve clearance ......... 140 Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) ..177 Checking the front valve clearance ........ 140 WIRING DIAGRAM ............178 Adjusting the front valve clearance........

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION 1 M EANS OF REPRESENTATION Symbols used The following explains the meaning of specific symbols. Identifies an expected reaction (e.g., of an operation or a function). Identifies an unexpected reaction (e.g., of an operation or a function). Identifies a page reference (more information is provided on the specified page).

  • Page 8: Important Notes

    Warranty The maintenance work described in the greasing and service table must be carried out exclusively in an authorized KTM-RC8 work- shop and confirmed in the service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for dam- age resulting from manipulation and/or other changes to the vehicle.

  • Page 9: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 3 L OCATION OF SERIAL NUMBERS Chassis number/type label 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 10: Steering Damper Part Number

    LOCATION OF SERIAL NUMBERS Steering damper part number The steering damper part number is stamped on the top of the steering damper.  700226-01...

  • Page 11: Motorcycle

    MOTORCYCLE 4 M OTORCYCLE Jacking up motorcycle front Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle rear end. ( p.

  • Page 12: Starting

    MOTORCYCLE 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 13: 01/Fork, Triple Clamp

    01/FORK, TRIPLE CLAMP 5 0 1/FORK, TRIPLE CLAMP 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 14: Adjusting Spring Preload Of Fork

    01/FORK, TRIPLE CLAMP 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 stability.

  • Page 15: Vehicle Level

    01/FORK, TRIPLE CLAMP Vehicle level Warning Danger of accidents Modifications to the chassis can seriously alter the vehi- cle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new han- dling 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 16 01/FORK, TRIPLE CLAMP – Tighten screw  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 700352-10 – Tighten screw  Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) –...

  • Page 17: 02/Handlebar, Controls And Instruments

    02/HANDLEBAR, CONTROLS AND INSTRUMENTS 6 0 2/HANDLEBAR, CONTROLS AND INSTRUMENTS Adjusting basic position of clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 18: Adjusting Gas Bowden Cable

    700362-01 Adjusting gas Bowden cable – 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  –...

  • Page 19: 03/Frame

    03/FRAME 7 0 3/FRAME Footrest position The adjustable footrest system enables an individual setting of the footrest height and an individual adjustment of the operating elements. The lower footrest position enables a more comfortable knee angle, the upper footrest position a sporting sitting position and more forward-leaning freedom for use in racing. 700328-01 Adjusting footrest position Info...

  • Page 20: Rear Frame Position

    03/FRAME Rear frame position The frame rear height can be set to two different positions, enabling ergonomic adjust- ment of the seat height. Seat height (standard) 805 mm (31.69 in)  Seat height 825 mm (32.48 in)  400439-10 Adjusting the rear frame position Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics.
  • Page 21 03/FRAME – Tighten screw on the left and right sides of the vehicle.  Guideline Screw, subframe 25 Nm Loctite ® 243™ (18.4 lbf ft) 700330-01 Setting a lower seat position: – Remove screw with washer on the left and right sides of the vehicle. ...
  • Page 22 03/FRAME – When you screw in the rear left fixing screw, the plug-in cable binder is pushed  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 23: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM 8 0 4/SHOCK ABSORBER, SWINGARM Adjusting the low-speed compression damping of the shock absorber 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 main- tenance on it yourself.

  • Page 24: Adjusting Rebound Damping Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Adjusting rebound damping of the shock absorber 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 main- tenance on it yourself.

  • Page 25: Adjusting The Vehicle Level At The Rear

    04/SHOCK ABSORBER, SWINGARM – Tighten screw  Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) 700341-11 Adjusting the vehicle level at the rear 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 26: 05/Exhaust

    05/EXHAUST 9 0 5/EXHAUST Removing the exhaust cover completely – Remove the side covers. ( p. 36) – Remove screws  – Remove screws on both sides.  – Take off exhaust cover completely.  200532-10 Installing the exhaust cover completely –...
  • Page 27 05/EXHAUST – Unplug connector of the lambda probe (2nd cylinder). Open the cable binder.  200513-10 – Unplug connector of the lambda probe (1st cylinder).  200514-10 – Remove screw . Slide the clamp upward.  200515-10 – Remove screw .

  • Page 28: Installing The Exhaust System

    05/EXHAUST – Remove nuts . Remove the manifold at the front with the seals.  200518-10 – Remove nuts . Remove the manifold at the rear with the seals.  200519-10 Installing the exhaust system Info The radiator has only been removed to illustrate the procedure more clearly. –...
  • Page 29 05/EXHAUST – Position the main silencer. Mount and tighten screws with the washers.  Guideline Remaining chassis screws 25 Nm (18.4 lbf ft) 0 0 3 0 0 3 0 0 3 200517-02 – Position the clamp. Mount and tighten screw ...

  • Page 30: 06/Air Filter

    06/AIR FILTER 06/AIR FILTER Removing the air filter 10.1 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. –...
  • Page 31 06/AIR FILTER – Unplug the connector of the manifold absolute pressure sensor  – Take the manifold absolute pressure sensor out of the holder but do not detach the vacuum hoses. – Disconnect plug-in connector  – Take plug-in connector out of the holding bracket.

  • Page 32: Installing The Filter Box Bottom

    06/AIR FILTER Installing the filter box bottom 10.4 – Detach the filter box bottom from the handlebar. Mount drain hoses . Plug in the  connector of the intake air temperature sensor. – Position the filter box bottom. – Mount snorkel seals ...
  • Page 33 06/AIR FILTER – Fix plug-in connector with the holding bracket.  – Connect plug-in connector  – Mount manifold absolute pressure sensor and plug in the connector.  – Install the air filter. ( p. 28) 200498-11...

  • Page 34: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM 07/FUEL TANK, SEAT, TRIM Removing the seat 11.1 – Insert the ignition key in the seat lock and turn it anticlockwise.  – Raise the rear of the seat, push it towards the rear, and remove it upwards. 700245-01 Fitting the seat 11.2...

  • Page 35: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 36: Removing The Fuel Tank Guard

    07/FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 37: Installing The Fuel Tank Guard

    07/FUEL TANK, SEAT, TRIM – Remove screw  – Take off the fuel tank guard. 500246-10 Installing the fuel tank guard 11.8 Info The operations are the same on the left and right sides. – Position the fuel tank guard. –...

  • Page 38: 08/Mask, Fender, Decal

    08/MASK, FENDER, DECAL 08/MASK, FENDER, DECAL Removing the side covers 12.1 – Remove screws on both sides.  – Remove side covers on both sides.  Info Watch out for the projections on the inside cover. 200492-10 Installing the side covers 12.2 –...

  • Page 39: Installing The Inside Cover

    08/MASK, FENDER, DECAL – Remove screw  – Remove the screws of the EFI control unit . Unplug and remove the EFI control  unit. – Unplug the control unit of the electric starter lock  – Remove the overflow hose. Take off the right inside cover. 200495-12 Installing the inside cover 12.4...

  • Page 40: 09/Front Wheel

    09/FRONT WHEEL 09/FRONT WHEEL Removing front wheel 13.1 – Jack up the motorcycle rear end. ( p. 9) – Jack up the motorcycle at the front. ( p. 9) – Remove the screws from both brake calipers.  – Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc.

  • Page 41: Tire Condition Checking

    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 42: Checking The Front Brake Discs

    Danger of accidents Reduced braking effect caused by worn brake discs. – Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop. – Check the thickness of the brake disc in several places to see if it conforms to mea- surement ...

  • Page 43: 10/Rear Wheel

    10/REAR WHEEL 10/REAR WHEEL Removing rear wheel 14.1 – Jack up the motorcycle rear end. ( p. 9) – Remove nut . Remove chain adjuster . Withdraw the wheel spindle    700311-01 – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

  • Page 44: Installing The Rear Wheel - When Installing The Engine

    10/REAR WHEEL – Push the brake caliper support completely to the rear.  – Position the rear wheel, and position the brake caliper support between the rim and the brake disc. – Position the brake caliper on the brake disc. –...
  • Page 45 10/REAR WHEEL – Remove bushing and bushing . Clean and grease the roll surfaces of the bush-   ing and the shaft seal rings. Long-life grease ( p. 194) – Mount the bushings. – Clean the thread of the wheel spindle and nut. –...

  • Page 46: Tire Condition Checking

    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 47: Checking The Rear Brake Disc

    Danger of accidents Reduced braking effect caused by worn brake discs. – Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop. – Check the thickness of the brake disc in several places to see if it conforms to mea- surement ...

  • Page 48: Adjusting The Chain Tension

    10/REAR WHEEL – Lean the motorcycle on the side stand. – Shift into neutral. – In the area in front of where the chain passes through the link fork, push the chain upward and measure chain tension  Info The lower chain section must be taut.

  • Page 49: Checking Rear Sprocket / Engine Sprocket For 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 700303-01 have the necessary special tools. Checking chain sliding guard 14.13...
  • Page 50 10/REAR WHEEL – Remove the rear sprocket carrier. – Check the rear hub for damage and wear. » If the rear hub shock absorbers are damaged or worn: – Change the shock absorber. – Position the rear sprocket carrier. Info A set of bolts and shock absorbers with as little free play as possible increases the service life of the shock absorbers.

  • Page 51: 11/Wiring Harness, Battery

    11/WIRING HARNESS, BATTERY 11/WIRING HARNESS, BATTERY Removing the battery 15.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 52: Recharging The Battery

    11/WIRING HARNESS, BATTERY – Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Reconnect the positive (plus) cable of the battery.  – Position positive terminal cover. 700277-11 – Reconnect the negative (minus) cable of the battery.

  • Page 53: Changing The Main Fuse

     – Fit a new main fuse. Fuse (58011109130) ( p. 168) Info If the new fuse burns out, contact an authorized KTM-RC8 workshop. – Attach the protection covers  – Fit the seat. ( p. 32)

  • Page 54: Changing The Fuses Of Individual Power Consumers

    168) Info If the new fuse burns out after it is inserted, it is important that you 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 55: 13/Brake System

    13/BRAKE SYSTEM Brake linings 16.1 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. The structure and friction coefficient of the brake linings, and therefore the brake power, can vary considerably from the original KTM brake lin- ings.

  • Page 56: Topping Up Brake Fluid Of Front Brake

    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 work- shop. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 57: Checking Rear Brake Fluid Level

    Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey. 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 work- shop. – Stand the vehicle upright.

  • Page 58: Adjusting The Footbrake Pedal Stub

    13/BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cover with membrane   – Top up the brake fluid to MAX level. Brake fluid DOT 4 / DOT 5.1 ( p. 192) – Refit screw with membrane. Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 59: Removing The Rear Brake System

    13/BRAKE SYSTEM Removing the rear brake system 16.11 – Remove the rear wheel. ( p. 41) – Unplug the brake light switch. Remove the cable clip. – Remove screw  – Remove screws . Take off the footrest bracket.  200525-10 –...

  • Page 60: 14/Light System, Instruments

    14/LIGHT SYSTEM, INSTRUMENTS 14/LIGHT SYSTEM, INSTRUMENTS Activating/deactivating ignition key 17.1 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.

  • Page 61: Setting Road Or Race Mode

    14/LIGHT SYSTEM, INSTRUMENTS – Pull out the orange programming key. All black ignition keys are deactivated. – Order a new black ignition key according to the key number on the KEYCODE- CARD and activate it. Activating ignition key: – Press the emergency OFF switch into the position –...

  • Page 62: Setting The Clock With Set Clock

    14/LIGHT SYSTEM, INSTRUMENTS Setting the clock with SET CLOCK 17.3 Condition The ignition is on. The motorcycle is standing. – Press the button and the button for 3 - 5 seconds. – Press the button once until the symbol is on SET CLOCK in the info display. –...

  • Page 63: Setting The Blank Time Of The Lap Button Lap Blank T

    14/LIGHT SYSTEM, INSTRUMENTS Setting the blank time of the LAP button LAP BLANK T 17.5 Condition The ignition is on. The motorcycle is standing. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol is on SETTINGS in the info display.

  • Page 64: Setting Fuel Reserve Display Tripf Reset

    14/LIGHT SYSTEM, INSTRUMENTS Setting fuel reserve display TRIPF RESET 17.7 Condition The ignition is on. The motorcycle is standing. – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol is on SETTINGS in the info display. –...

  • Page 65: Setting Temperature Unit Set °C/°F

    14/LIGHT SYSTEM, INSTRUMENTS Setting temperature unit SET °C/°F 17.9 Condition The ignition is on. The motorcycle is standing. – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol is on UNITS in the info display. –...

  • Page 66: Checking Headlight Adjustment

    14/LIGHT SYSTEM, INSTRUMENTS – Press the MODE button briefly. SERVICE RESET appears in the info display. ARE YOU SURE? flashes. – Press the button The menu is closed. – Press the button NEXT SERVICE AFTER is displayed. 400486-01 – Adjust the distance to the next service using the button and the button –...

  • Page 67: Changing The Parking Light Bulb

    14/LIGHT SYSTEM, INSTRUMENTS Changing the parking light bulb 17.14 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 68: Changing The Low Beam Bulb

    14/LIGHT SYSTEM, INSTRUMENTS – Position the lug of the lamp cover in the notch. Engage the latch.  – Check lighting function. 400422-12 – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. – Mount and tighten screws ...

  • Page 69: Change The High Beam Bulb

    14/LIGHT SYSTEM, INSTRUMENTS – Disconnect plug-in connector  – Push off the retaining clamp on both sides, squeeze and fold to the side.  – Remove headlight bulb  700295-01 – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7) ( p.
  • Page 70 14/LIGHT SYSTEM, INSTRUMENTS – Remove screws . Remove cover.  700297-01 – Release the latch  – Remove the lamp cover  700298-01 – Disconnect plug-in connector  – Push off the retaining clamp on both sides, squeeze and fold to the side. ...
  • Page 71 14/LIGHT SYSTEM, INSTRUMENTS – Position cover. Info Check for correct positioning and freedom of movement of the brake lines. – Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 700335-10...

  • Page 72: 30/Engine

    30/ENGINE 30/ENGINE Removing the engine 18.1 – Jack up the motorcycle rear end. ( p. 9) – Dismount the fuel tank. ( p. 32) – Remove the inside cover. ( p. 36) – Remove the air filter. ( p. 28) –...
  • Page 73 30/ENGINE – Remove screws . Remove the slave cylinder with the spacer and sleeves.  – Remove screws . Take off the engine sprocket cover.  200521-10 – Shift into first gear. Info The purpose is to loosen the nut of the engine sprocket. –...

  • Page 74: Preparing The Engine For Installation

    30/ENGINE – Remove nut . Pull out the pin of the bell crank on the frame.  – Remove the nut of the swingarm pivot. Pull out the swingarm pivot. – Take off the swingarm with the shock absorber. 200529-10 –...
  • Page 75 30/ENGINE – Raise the rear of the motorcycle. Position the engine in the frame. – Mount screws with the washers on both sides but do not tighten them yet.  – Secure the motorcycle against falling over with belts. 200530-11 –...
  • Page 76 30/ENGINE – Position the horn holder. Mount and tighten screws  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) 200524-11 – Position the footrest bracket. Mount and tighten screws  Guideline Screw, front footrest 25 Nm Loctite ® 243™ bracket (18.4 lbf ft) –...
  • Page 77 9) – Fill up with engine oil. ( p. 158) – Take a short test ride. – Read the fault memory with KTM DIA. – Check the engine for leakage. – Check the engine oil level. ( p. 155) –...

  • Page 78: Setting The Engine To Ignition Top Dead Center Of The Rear Cylinder

    30/ENGINE Setting the engine to ignition top dead center of the rear cylinder 18.4 Condition The valve cover has been removed. – Remove screw of the generator cover.  200539-11 – Turn the crankshaft counterclockwise until markings of the rear camshafts are ...

  • Page 79: 30/Disassembling The Engine

    30/DISASSEMBLING THE ENGINE 30/DISASSEMBLING THE ENGINE Clamping the engine into the engine work stand 19.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 198) Engine holder (61229002000) ( p. 198) – Mount the engine on special tool ...

  • Page 80: Setting The Engine To Ignition Top Dead Center Of The Rear Cylinder

    30/DISASSEMBLING THE ENGINE Setting the engine to ignition top dead center of the rear cylinder 19.5 – Remove screw of the generator cover.  200308-10 – Turn the crankshaft counterclockwise until markings of the rear camshafts are  flush with the edge of the cylinder head. 200309-10 –...

  • Page 81: Removing The Heat Exchanger

    30/DISASSEMBLING THE ENGINE Removing the heat exchanger 19.8 – Remove screws of heat exchanger   – Remove the heat exchanger. 200314-10 – Remove O-rings and sleeves   – Remove seal  200315-10 Removing the rear timing chain tensioner 19.9 –...

  • Page 82: Removing The Rear Cylinder Head

    30/DISASSEMBLING THE ENGINE Removing the rear cylinder head 19.11 – Remove nuts with the washers.  – Alternately loosen screws and remove them.  – Take off the cylinder head. Remove the cylinder head gasket. 200321-10 Removing the rear piston 19.12 –...

  • Page 83: Removing The Front Camshafts

    30/DISASSEMBLING THE ENGINE Removing the front camshafts 19.15 – Remove spark plug shaft insert  – Loosen and remove screws from the outside to the inside.  Info The cams should not activate the valves. – Remove the camshaft bearing bridge. 200332-10 –...

  • Page 84: Removing The Generator Cover

    30/DISASSEMBLING THE ENGINE Removing the generator cover 19.18 – Remove screws  200344-10 – Screw in special tool and pull off the generator cover.  Extractor (61229010000) ( p. 199) Info Gently strike the generator cover with a rubber mallet to prevent strain. –...

  • Page 85: Removing The Idler And Timing Chain On The Left

    30/DISASSEMBLING THE ENGINE – Screw the special tool into the crankshaft. Pressure piece (61229008000) ( p. 199) – Mount special tool on the rotor, apply counterpressure, and pull off the rotor by  screwing in the screw. Extractor (58429009000) ( p.

  • Page 86: Removing The Oil Filter

    30/DISASSEMBLING THE ENGINE Removing the oil filter 19.23 – Remove screws . Take off oil filter cover with the O-ring.   – Pull oil filter element out of the oil filter case.  Circlip pliers reverse (51012011000) ( p. 195) 200481-10 Removing the balancer shaft 19.24...

  • Page 87: Removing The Left Suction Pump

    30/DISASSEMBLING THE ENGINE – Remove contact pin and the contact spring.  200360-10 Removing the left suction pump 19.27 – Remove screws  – Remove oil pump cover  – Remove seal  200361-10 – Remove external rotor and internal rotor ...

  • Page 88: Removing The Water Pump Wheel

    30/DISASSEMBLING THE ENGINE Removing the water pump wheel 19.28 – Remove screws  – Take off the water pump cover. 200397-10 – Remove dowels  – Remove screw . Take off the water pump wheel with the washer below it. ...

  • Page 89: Removing The Clutch Facing

    30/DISASSEMBLING THE ENGINE Removing the clutch facing 19.31 – Loosen screws of pressure cap in a crisscross pattern and remove them   together with the spring retainers and the clutch springs. – Take off pressure cap  – Take off push rod ...

  • Page 90: Removing The Primary Gear

    30/DISASSEMBLING THE ENGINE Removing the primary gear 19.33 – Loosen nut of primary gear and remove it together with the washer.   Info Left-handed thread! Make sure that the crankshaft is blocked. 200412-10 – Remove the primary gear with special tool ...

  • Page 91: Removing The Shift Shaft

    30/DISASSEMBLING THE ENGINE – Remove external rotor and internal rotor   – Remove pin  – Remove pins  200416-10 Removing the shift shaft 19.35 – Push sliding plate away from the shift drum locating . Remove shift shaft ...

  • Page 92: Removing The Left Engine Case

    30/DISASSEMBLING THE ENGINE Removing the left engine case 19.38 200421-10 – Remove screws   – Swing the left section of the engine case upward. Remove screw  – Loosen the left section of the engine case by striking it lightly with a plastic hammer and remove it. –...

  • Page 93: Removing The Transmission Shaft

    30/DISASSEMBLING THE ENGINE – Remove internal rotor and pin from the oil pump shaft    – Remove external rotor  200426-10 Removing the transmission shaft 19.41 – Remove shift rails  200427-10 – Swing shift forks to one side. ...

  • Page 94: Removing The Oil Spray Tube

    30/DISASSEMBLING THE ENGINE Removing the oil spray tube 19.42 – Remove oil spray tube . Remove O-rings   200432-10 Removing the timing chain rails of the right engine case section 19.43 – Remove screw . Remove timing chain guide rail ...

  • Page 95: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS 30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 20.1 – Remove studs  200442-10 – Remove jet  – Remove oil jets  200440-10 – Remove bearing retainers ...

  • Page 96: Removing The Main Bearing Of The Right Engine Case Section

    30/ENGINE - WORK ON INDIVIDUAL PARTS – After the engine case section has cooled, check that the bearings are firmly seated. Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed.

  • Page 97: Selecting The Main Bearing Shells

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Place the engine case section on special tool  Press sleeve (61229045000) ( p. 201) – Place special tool with the smaller diameter on the bearing shells and press from  the inside to the outside. Press drift/press sleeve (61229044000) ( p.

  • Page 98: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position bearing shell bracket . Mount and tighten the screws.  Guideline Screw, bearing retainer 6 Nm Loctite ® 243™ (4.4 lbf ft) 200435-11 Work on the left section of the engine case 20.5 –...
  • Page 99 30/ENGINE - WORK ON INDIVIDUAL PARTS – Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to the outside, all the way to the stop or so it is flush. Info When pressing the bearing in, ensure that the engine case section is level to prevent damage.

  • Page 100: Removing The Left Main Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the left main bearing 20.6 – Remove the screws and take off bearing shell bracket  200443-10 – Mark joint of the main bearing shells as shown in the figure.  200444-10 – Place the engine case section on special tool ...

  • Page 101: Changing The Conrod Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Position bearing shell bracket . Mount and tighten the screws.  Guideline Screw, bearing retainer 6 Nm Loctite ® 243™ (4.4 lbf ft) 200443-11 Changing the conrod bearing 20.8 Info Perform the operation on both connecting rods. –...

  • Page 102: Work On The Clutch Cover

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Oil the bearing shells. – Position the connecting rod bearing cap according to the markings made when they were disassembled. Mount the new connecting rod screws and tighten them using the special tool. Guideline Screw, conrod bearing M10x1...

  • Page 103: Changing The Step Bearing Of The Crankshaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in outer shaft seal ring fully, with the open side flush and facing outwards.  – Insert water pump cover  200456-10 Changing the step bearing of the crankshaft 20.10 – Mark the position of the bearing joint ...

  • Page 104: Checking The Radial Clearance Of The Bottom Connecting Rod Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the radial clearance of the bottom connecting rod bearing 20.11 Info Perform the operation on both connecting rods. – Position the bearing shells. Insert the Plastigauge measuring strips offset by 90°  from the bearing joint. Plastigauge measuring strips (60029012000) ( p.

  • Page 105: Checking/Measuring The Piston

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 196) ≤ 0.05 mm (≤ 0.002 in) Cylinder/cylinder head - sealing area distortion »...

  • Page 106: Checking The Piston Ring End Gap

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Piston size is marked on the piston head.  200476-10 Checking the piston ring end gap 20.14 – Remove the piston ring from the piston. – Place the piston ring in the cylinder and align it with the piston. Guideline Under the upper edge of the cylinder 10 mm (0.39 in)
  • Page 107 30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove plugs with the O-ring.  – Pull out cam lever axle with a suitable M5 screw and remove the cam lever.  200467-10 – Remove shims and label the installation position.  200468-10 –...
  • Page 108 30/ENGINE - WORK ON INDIVIDUAL PARTS – Tension the valve spring with a special tool. Valve spring mounter (59029019000) ( p. 195) Valve spring mounting device (78029060000) ( p. 202) – Mount valve keys . Release the tension on the valve spring. ...

  • Page 109: Checking The Cylinder Head

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount screw  Guideline Plug, vacuum connection 5 Nm Loctite ® 243™ (3.7 lbf ft) – Mount vacuum connection  Guideline Vacuum connection 5 Nm Loctite ® 243™ (3.7 lbf ft) – Mount and grease O-rings ...

  • Page 110: Work On The Right Idler

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the valve stem diameter. Valve - valve stem diameter Exhaust 5.893… 5.970 mm (0.23201… 0.23504 in) Intake 5.965… 5.980 mm (0.23484… 0.23543 in) » If the measured value does not equal the specified value: –...

  • Page 111: Checking The Timing Assembly

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the timing assembly 20.19 – Clean all parts well. 0 0 2 – Check idler for damage and wear.  » If there is damage or wear: 0 0 4 – Change the idler. –...

  • Page 112: Checking The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Release the timing chain tensioner. The latching system locks and the piston stops moving. End position of piston after latching 3 mm (0.12 in) Info This position is necessary for installation. If the timing chain tensioner is now pressed in once more (while it is installed) and then pulled out no more than halfway (preventing it from coming out fully), the latching system locks and the timing chain tensioner can no longer be compacted;...

  • Page 113: Checking The Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the clutch 20.23 0 0 4 0 0 3 0 0 8 0 0 5 0 0 9 0 0 6 0 0 7 0 0 1 0 0 2 200457-01 – Check pressure piece for damage and wear.

  • Page 114: Checking The Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the thickness of intermediate clutch discs  Intermediate disk - thickness New condition 1.95… 2.05 mm (0.0768… 0.0807 in) Wear limit 1.85 mm (0.0728 in) » If the intermediate clutch discs do not meet specifications: –...

  • Page 115: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check springs of the shift rails for damage and wear.  » If the spring is broken or worn: – Change the spring of the shift rail. – Check the shift rails on a flat surface for run-out. ...

  • Page 116: Dismantling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove the third/fourth-gear sliding gear  – Remove lock ring  – Remove stop disk and the fifth-gear idler gear   – Remove needle bearing  – Remove needle bearing using a suitable tool. ...

  • Page 117: Checking The Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the transmission 20.28 0 0 2 0 0 1 0 0 4 0 0 4 0 0 6 0 0 6 0 0 7 0 0 5 0 0 1 0 0 5 0 0 6 0 0 8 0 0 4...

  • Page 118: Assembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling the main shaft 20.29 Info Use new lock rings and new stop disks with every repair. – Oil all parts carefully before assembling. – Check the transmission. ( p. 115) 0 0 3 0 0 1 0 0 2 0 0 6...
  • Page 119 30/ENGINE - WORK ON INDIVIDUAL PARTS 0 0 b r 0 0 b q 0 0 b p 0 0 b o 0 0 b s 0 0 b n 0 0 b l 0 0 b m 0 0 9 0 0 8 0 0 b k 0 0 7...

  • Page 120: 30/Assembling The Engine

    30/ASSEMBLING THE ENGINE 30/ASSEMBLING THE ENGINE Installing the timing chain rails of the left engine case section 21.1 – Position timing chain guide rail . Mount and tighten screw   Guideline Screw, timing chain guide 15 Nm Loctite ® 243™...

  • Page 121: Installing The Oil Spray Tube

    30/ASSEMBLING THE ENGINE Installing the oil spray tube 21.3 – Mount new O-rings on oil spray tube   – Mount the oil spray tube. must engage in recess   200433-01 Installing the transmission shaft 21.4 – Clamp the right section of the engine case. Engine work stand (61229001000) ( p.

  • Page 122: Installing The Middle Suction Pump

    30/ASSEMBLING THE ENGINE – Swing shift forks to one side.  Info Watch out for the shift rollers  – Insert shift drum into the bearing seat.  – Let the shift forks engage in the shift grooves. 200428-11 – Mount shift rails with the pressure springs.

  • Page 123: Installing The Left Engine Case

    30/ASSEMBLING THE ENGINE Installing the left engine case 21.7 – Mount dowels  – Mount gasket  – Check that dowel is correctly seated.  200422-11 – Degrease the sealing area and coat thinly with sealant. Loctite ® 5910 Info Only coat the sealing area around the outside (see figure).

  • Page 124: Installing The Locking Lever

    30/ASSEMBLING THE ENGINE Installing the locking lever 21.8 – Position locking lever with sleeve and spring    – Mount and tighten screw  Guideline Screw, locking lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 200420-11 Installing the shift drum locating 21.9 –...

  • Page 125: Installing The Force Pump

    30/ASSEMBLING THE ENGINE Installing the force pump 21.11 – Mount pins  – Mount pin  – Mount internal rotor and external rotor   Marking of the internal rotor is visible after mounting while that of the exter-  nal rotor is not.

  • Page 126: Installing The Left Suction Pump

    30/ASSEMBLING THE ENGINE Installing the left suction pump 21.12 – Mount pin  – Mount internal rotor and external rotor   Marking of the internal rotor is visible after mounting while that of the exter-  nal rotor is not. –...

  • Page 127: Installing The Primary Gear

    30/ASSEMBLING THE ENGINE Installing the primary gear 21.14 – Ensure that the spring washer is seated properly. – Mount primary gear  – Mount the washer and nut and tighten the nut.  Guideline Nut, primary gear M33LHx1.5 130 Nm Loctite ®...

  • Page 128: Installing The Clutch Facing

    30/ASSEMBLING THE ENGINE – Insert special tool  Clutch holder (61229003000) ( p. 198) – Mount the washer and nut and tighten the nut.  Guideline Nut, inner clutch hub M22x1.5 130 Nm Loctite ® 243™ (95.9 lbf ft) 200408-11 Installing the clutch facing 21.16 –...

  • Page 129: Installing The Idler And Timing Chain On The Right

    30/ASSEMBLING THE ENGINE Installing the idler and timing chain on the right 21.17 – Position timing chain according to the direction of travel.  – Place the timing chain over the toothing of idler . Align markings    –...

  • Page 130: Installing The Water Pump Wheel

    30/ASSEMBLING THE ENGINE Installing the water pump wheel 21.19 – Mount the washer and water pump wheel. – Mount and tighten screw  Guideline Screw, water pump wheel 10 Nm Loctite ® 243™ (7.4 lbf ft) – Mount dowels  –...

  • Page 131: Installing The Balancer Shaft

    30/ASSEMBLING THE ENGINE Installing the balancer shaft 21.22 – Mount the rear washer and needle bearing. – Mount balancer shaft  Markings are aligned.   – Mount washer  200357-10 Installing the idler and timing chain on the left 21.23 –...

  • Page 132: Installing The Oil Filter

    30/ASSEMBLING THE ENGINE Installing the oil filter 21.24 – Tilt the engine sideways and fill the oil filter housing to about ⅓ full with engine oil. – Insert oil filter  – Lubricate the O-ring of the oil filter cover. Mount oil filter cover ...

  • Page 133: Installing The Torque Limiter And Idler

    30/ASSEMBLING THE ENGINE Installing the torque limiter and idler 21.26 – Mount the rear washer, needle bearing, idler and front washer.  – Mount torque limiter with the rear washer.  200347-11 Installing the ignition pulse generator 21.27 – Position the ignition pulse generator ...

  • Page 134: Installing The Rear Piston

    30/ASSEMBLING THE ENGINE Installing the rear piston 21.30 – Shift the joint of the piston rings by 120°. – Place the oiled piston on the cylinder. Tighten the piston rings using the special tool. Piston ring mounting tool (60029015000) ( p.

  • Page 135: Installing The Rear Cylinder Head

    30/ASSEMBLING THE ENGINE – Position the new piston pin retainer. Info For clarity, the following steps are illustrated using a disassembled piston. – Insert the special tool and firmly press it toward the piston. – Turn the special tool counterclockwise, thereby pressing the piston pin retainer into the groove.

  • Page 136: Installing The Rear Camshaft

    30/ASSEMBLING THE ENGINE Installing the rear camshaft 21.32 – Pull up the timing chain and insert intake camshaft  Info The intake camshaft is labeled with INRE. – Place the timing chain over the rear sprocket of the intake camshaft. Marking is aligned.

  • Page 137: Setting The Engine To Ignition Top Dead Center Of The Front Cylinder

    30/ASSEMBLING THE ENGINE Setting the engine to ignition top dead center of the front cylinder 21.34 – Remove special tool  – Keep the timing chain tensioned. – Turn the crankshaft counterclockwise by the specified value. Guideline 1 turn 200328-10 –...
  • Page 138 30/ASSEMBLING THE ENGINE – Position the new cylinder base gasket  200342-10 – Ensure that piston marking faces the outfeed side.  200340-10 – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. 200343-10 –...

  • Page 139: Installing The Front Cylinder Head

    30/ASSEMBLING THE ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the dowel pins engage. 200337-10 Installing the front cylinder head 21.36 – Mount the new cylinder head gasket. – Mount the cylinder head. Mount and tighten the new cylinder head screws ...

  • Page 140: Installing The Front Timing Chain Tensioner

    30/ASSEMBLING THE ENGINE – Thoroughly clean all oil jets and blow them out with compressed air. – Position the camshaft bearing bridge. – Mount screws and tighten them from the outside to the inside.  Guideline Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Screw, camshaft bearing support Step 1...

  • Page 141: Installing The Oil Filler Tube

    30/ASSEMBLING THE ENGINE Installing the oil filler tube 21.40 – Mount the oil filler tube with the O-ring. – Mount and tighten screws  Guideline Remaining engine screws 10 Nm (7.4 lbf ft) 200313-10 Installing the starter motor 21.41 – Grease O-ring .

  • Page 142: Adjusting The Rear Valve Clearance

    30/ASSEMBLING THE ENGINE Adjusting the rear valve clearance 21.43 – Remove the rear timing chain tensioner. ( p. 79) – Remove the rear camshaft. ( p. 79) – Swing up cam lever  – Remove shims and set them down according to the installation position. ...

  • Page 143: Installing The Front Valve Cover

    30/ASSEMBLING THE ENGINE – Remove special tool . Mount and tighten screw   Guideline Plug, crankshaft retainer 15 Nm (11.1 lbf ft) 200310-11 Installing the front valve cover 21.46 – Position the valve cover seal. – Put the valve cover in place with the seal. Mount and tighten screws ...

  • Page 144: 32/Clutch

    32/CLUTCH 32/CLUTCH Checking fluid level of hydraulic clutch 22.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 145: 34/Shift Mechanism

    34/SHIFT MECHANISM 34/SHIFT MECHANISM Adjusting shift lever stub 23.1 – Remove the screw with the shift lever stub.  – Position the shift lever stub with the screw in one of the holes according to the  desired lever length. Guideline Standard Central hole...
  • Page 146 34/SHIFT MECHANISM – The shift rod can be mounted both on the shift lever variably at an upper or lower position, and on the reverse gear change of the shift shaft in two different posi- tions. Guideline 0 0 A Standard Shift lever: lower drill hole, ...

  • Page 147: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM 35/WATER PUMP, COOLING SYSTEM Checking the coolant level 24.1 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 cooling system to cool down.

  • Page 148: Removing The Radiator

    35/WATER PUMP, COOLING SYSTEM Removing the radiator 24.3 – Remove the exhaust cover completely. ( p. 24) – Remove the inside cover. ( p. 36) – Remove the drain plug of water pump and of radiator . Completely drain the ...

  • Page 149: Adding Coolant/Bleeding The Cooling System

    35/WATER PUMP, COOLING SYSTEM – Mount and tighten screw  Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) – Mount the radiator hose. Position and tighten hose clamps  200506-11 – Mount radiator hoses . Position and tighten the hose clamps. ...

  • Page 150: Filling The Cooling System Compensating Tank

    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 failure. – Have the coolant changed by an authorized KTM-RC8 workshop. – Check the coolant level. ( p.

  • Page 151: 36/Cylinder Head

    36/CYLINDER HEAD 36/CYLINDER HEAD Checking the valve clearance 25.1 – Remove the filter box bottom. ( p. 28) – Remove the side covers. ( p. 36) – Detach connector of the ignition coil.  – Remove the ignition coil. – Remove screws and take off the valve cover.

  • Page 152: Adjusting The Rear Valve Clearance

    36/CYLINDER HEAD – Mount and tighten the screw of generator cover  Guideline Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft) 200539-10 – Mount and tighten the spark plug using a special tool. Spark plug wrench (75029172000) ( p.

  • Page 153: Removing The Rear Camshaft

    36/CYLINDER HEAD Removing the rear camshaft 25.4 – Remove the rear timing chain tensioner. ( p. 152) – Remove spark plug shaft insert  – Loosen and remove screws from the outside to the inside.  Info The cams should not activate the valves. –...

  • Page 154: Removing The Front Camshafts

    36/CYLINDER HEAD Removing the front camshafts 25.6 – Remove the front timing chain tensioner. ( p. 153) – Remove spark plug shaft insert  – Loosen and remove screws from the outside to the inside.  Info The cams should not activate the valves. –...

  • Page 155: Installing The Rear Timing Chain Tensioner

    36/CYLINDER HEAD Installing the rear timing chain tensioner 25.9 – Prepare the timing chain tensioner for installation. ( p. 109) – After it has been positioned in the installation location, insert timing chain ten- sioner with a new O-ring.  –...

  • Page 156: 38/Lubrication System

    38/LUBRICATION SYSTEM 38/LUBRICATION SYSTEM Oil circuit 26.1 400492-60 Oil circuit of middle suction pump Oil screen of oil drain plug in gearbox Middle suction pump Heat exchanger Oil exit in oil tank Oil circuit of left suction pump Crankcase Left suction pump Lubricating slots in gearbox Oil circuit of force pump Oil screen of oil drain plug in oil tank...

  • Page 157: Checking Engine Oil Level

    38/LUBRICATION SYSTEM Checking engine oil level 26.2 Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Remove oil dipstick . Check the engine oil level in the measurement range. ...
  • Page 158 38/LUBRICATION SYSTEM – Remove screws  – Take off the left exhaust cover  700302-10 – 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 159: Removing Oil Filter

    38/LUBRICATION SYSTEM – Position the left exhaust cover  – Mount and tighten screws  Guideline Remaining chassis screws 5 Nm (3.7 lbf ft) 700302-10 Removing oil filter 26.5 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. –...

  • Page 160: Fitting Oil Filter

    38/LUBRICATION SYSTEM Fitting oil filter 26.6 – Insert the oil filter  – Lubricate the O-ring of the oil filter cover. Fit the oil filter cover  – Mount and tighten screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 700291-01 Filling up with engine oil 26.7...

  • Page 161: Topping Up Engine Oil

    38/LUBRICATION SYSTEM Topping up engine oil 26.8 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Check the engine oil level. ( p. 155) Engine oil (SAE 10W/50) ( p. 192) – Remove the dipstick and top up the engine oil.

  • Page 162: Immobilizer Flash Code

    IMMOBILIZER FLASH CODE IMMOBILIZER FLASH CODE Fault Description Possible cause Action – Immobilizer indicator lamp All ignition keys inactive Activate/deactivate the flashes 1x short, 1 second ignition key. ( p. 58) pause, 2x short – Immobilizer indicator lamp Malfunction, antenna of immo- Check the antenna of the flashes 1x short, 1 second bilizer control unit...

  • Page 163: Engine Control Error Code

    ENGINE CONTROL ERROR CODE ENGINE CONTROL ERROR CODE Fault Possible cause Action – P0031 Malfunction or short circuit to ground in Check heating of lambda probe (cylin- lambda probe heating circuit (cylinder 1) der 1). – P0032 Malfunction or short circuit to plus in Check heating of lambda probe (cylin- lambda probe heating circuit (cylinder der 1).
  • Page 164 ENGINE CONTROL ERROR CODE Fault Possible cause Action – P0638 Malfunction in throttle valve stepper cir- Check circuit B of throttle stepper cuit, circuit B motor. – P1105 Connection of pressure sensor, induction Check pressure sensor, induction mani- manifold (cylinder 1) leaky fold (cylinder 1).

  • Page 165: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,150 cm³ (70.18 cu in) Stroke 69 mm (2.72 in) Bore 103 mm (4.06 in) Compression ratio 12,5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 42 mm (1.65 in)

  • Page 166: Technical Data - Tolerance, Wear Limits Of Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Camshaft - cam height Intake 39.34… 39.44 mm (1.5488… 1.5528 in) Exhaust 38.59… 38.69 mm (1.5193… 1.5232 in) Camshaft - bearing pin 23.960… 23.980 mm (0.94331… 0.94409 in) Camshaft bearing - radial clearance New condition 0.020…...
  • Page 167 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Connecting rod - radial clearance of lower conrod bearing New condition 0.030… 0.060 mm (0.00118… 0.00236 in) Wear limit 0.080 mm (0.00315 in) Connecting rod - large end width 20.950… 21.000 mm (0.8248… 0.82677 in) Crankshaft - axial clearance New condition 0.15…...

  • Page 168: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) ® Screw, gear sensor 3 Nm (2.2 lbf ft) Loctite 243™ ® Screw, pulse generator 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 169 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Plug, cam lever axis M10x1 15 Nm (11.1 lbf ft) Cylinder head screw M11x1.5 Tightening sequence: lubricated with engine oil...

  • Page 170: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS 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 125 mm (4.92 in) Brake system front Double disc brake with radially screwed four-piston brake...

  • Page 171: Lighting Equipment

    120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro For further information, see the Service section under: http://www.ktm.com Capacity - fuel 32.2 Total fuel tank capacity, 16.5 l (4.36 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 172: Technical Data - Fork

    TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number 05.18.7D.07 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...

  • Page 173: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 17.18.7D.07 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...

  • Page 174: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ ® Screw, brake fluid reservoir of rear 5 Nm (3.7 lbf ft) Loctite 243™ brake – Screw, brake line holder 5 Nm (3.7 lbf ft) –...
  • Page 175 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, sidestand 35 Nm (25.8 lbf ft) Loctite 243™ ® Screw, connecting lever, shock 45 Nm (33.2 lbf ft) Loctite 243™ absorber deflector – Remaining chassis screws 45 Nm (33.2 lbf ft) – Nut of bell crank on frame M14x1.5 100 Nm (73.8 lbf ft)

  • Page 176: Cleaning/Conservation

    CLEANING/CONSERVATION CLEANING/CONSERVATION Cleaning motorcycle 36.1 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 electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 177: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle rear end. ( p. 9) –...

  • Page 178: Greasing And Service Table

    GREASING AND SERVICE TABLE GREASING AND SERVICE TABLE Important service tasks to be carried out by an authorized KTM-RC8 workshop. 38.1 K10N K75A K150A Engine Change the engine oil and filter, clean the oil screen. ( p. 155) • •...

  • Page 179: Important Service Tasks To Be Carried Out By An Authorized Ktm-Rc8 Workshop. (As Additional Job)

    K75A: every 7,500 km (4,660 mi) K150A: every 15,000 km (9,320 mi) / after every sporting use J1A: annually J2A: every 2 years Important service tasks to be carried out by an authorized KTM-RC8 workshop. (as additional job) 38.2 K150A K300A Completely service fork.

  • Page 180: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM 1 of 3 39.1 82,177 175,176,144,153,169,182 98,147,152 54,55 27,28,30,39,46,66 24,25 7,8,9,10,14 AU/2 36,37 BI/2 500243-01...
  • Page 181 WIRING DIAGRAM Components Plug-in connector for alarm system (optional) F1‑2 Battery A7 Generator B‑C8 Starter relay with main fuse A6 Fuel pump relay F4‑5 Light relay F5‑6 Power relay F6 Start auxiliary relay F7 Starter motor A‑B6 Fuel pump F5 Voltage regulator/rectifier B8 Ignition/steering lock, antenna EWS control unit A1‑2 Emergency OFF switch, electric starter button A2‑3...
  • Page 182 WIRING DIAGRAM Red-violet Blue-red Brown Brown Brown Brown Black Violet White-black Red-violet Brown White-red Blue-red Yellow-orange Brown White-red White-red Brown Yellow Yellow-red Green-orange Blue-gray Yellow-orange White-red Red-violet Blue-red Yellow-orange White-red Yellow-orange Green Black-green White-red White-red Yellow-orange Yellow-orange Yellow-orange Yellow-orange White-red Yellow-orange...
  • Page 183 WIRING DIAGRAM...

  • Page 184: Of 3

    WIRING DIAGRAM 2 of 3 39.2 100,148,224 99,151 156,179,218 /1.B4 /1.B4 CQ/16 -X300 CP/16 238,239 500244-01...
  • Page 185 WIRING DIAGRAM Components EWS control unit A3 EFI control unit F4‑7 Control unit of electric starter lock A5 Side stand switch A4 Intake air temperature sensor F1 Roll angle sensor F1 Lambda probe (cylinder 2) F1‑2 Lambda probe (cylinder 1) F2 Pressure sensor, ambient air F2‑3 Pressure sensor, induction manifold (cylinder 2) F3 Pressure sensor, induction manifold (cylinder 1) F3...
  • Page 186 WIRING DIAGRAM Blue Green-gray Yellow-blue White-yellow Orange White-pink Brown Yellow-brown Gray Black-green Brown Orange White-violet Pink Blue Black Orange White-orange Black Brown-red Brown Green Black-green White-red Orange Black-blue Brown White-blue Brown-violet Black-blue White-blue Black-brown Black-green White Brown Yellow Brown White-blue Black-blue Brown Black...
  • Page 187 WIRING DIAGRAM Black Green-red Brown Brown-violet Blue Red-violet Black Blue-red Black Black-green Orange Yellow Pink Blue-orange Blue-pink Black-gray Yellow-orange White-red Brown Brown Green White-green Black-blue White-blue Brown-gray Yellow-green Green-orange Blue-brown Black Orange Blue Blue Pink Yellow Brown Black-green Orange Orange Orange Blue Blue...
  • Page 188 WIRING DIAGRAM Gray Black-blue Green-red White Blue-orange...
  • Page 189 WIRING DIAGRAM...

  • Page 190: Of 3

    WIRING DIAGRAM 3 of 3 39.3 pos. high -B10 -B14 t° AR/3 CW/2 CW/2 AM/3 CX/2 CX/2 EW/4 CX/2 AT/2 AK/2 CW/2 AL/2 AH/2 ED/32 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 170,171 139,160 79,134...
  • Page 191 WIRING DIAGRAM Components Wheel speed sensor D1 Fuel level indicator A4 Ambient air temperature sensor B1 Coolant temperature sensor (2nd cylinder) F3 Coolant temperature sensor (1st cylinder) F2 Low beam, high beam, parking light D‑E1 Front right flasher B1 Front left flasher E1 Horn F5‑6 Rear right flasher C8 Brake/tail light C‑D8...
  • Page 192 WIRING DIAGRAM Violet Yellow-blue Yellow-green Black-green Blue-red Black Brown Gray Yellow-blue Green-gray Yellow-green Red-violet Brown Brown-red Brown Brown Brown Brown Brown Black Violet Yellow Yellow Brown Blue Gray Yellow-green Yellow-green Black-orange Yellow-orange Brown White-red Yellow-orange Brown-violet Black-blue White-blue Black-brown Yellow-green Brown Blue Black-green...
  • Page 193 WIRING DIAGRAM Yellow Yellow-blue White-blue Black-blue Brown Yellow-orange Brown Brown Brown Brown Violet Black White...

  • Page 194: Substances

    – 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 products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 195 – ISO VG (15) Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...

  • Page 196: Auxiliary Substances

    AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Supplier ® Motorex –...

  • Page 197: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Bearing puller Article no.: 15112017000 400037-01 Circlip pliers reverse Article no.: 51012011000 400059-01 Extractor Article no.: 58429009000 400073-01 Valve spring mounter Article no.: 59029019000 400101-01 Limit plug gauge Article no.: 59029026006 400104-01...
  • Page 198 SPECIAL TOOLS Feeler gauge Article no.: 59029041100 400110-01 Graduated disc Article no.: 60029010000 400120-01 Plastigauge measuring strips Article no.: 60029012000 400122-01 Piston ring mounting tool Article no.: 60029015000 400123-01 Insert for bearing puller Article no.: 60029018000 Feature 23… 28 mm (0.91… 1.1 in) 400038-01...
  • Page 199 SPECIAL TOOLS Step bearing tool Article no.: 60029046028 400136-01 Pliers for spring-loaded band-type clamp Article no.: 60029057100 400085-01 Multi-tooth wrench socket 10 mm; ½" drive Article no.: 60029075000 400145-01 Work stand rear Article no.: 61029055100 500077-01 Work stand adapter Article no.: 61029055120 700270-01...
  • Page 200 SPECIAL TOOLS Work stand front Article no.: 61029055300 500078-01 Engine work stand Article no.: 61229001000 200306-01 Engine holder Article no.: 61229002000 200307-01 Clutch holder Article no.: 61229003000 200308-01 Mounting sleeve Article no.: 61229005000 200309-01...
  • Page 201 SPECIAL TOOLS Pressure piece Article no.: 61229008000 200438-01 Extractor Article no.: 61229010000 200310-01 Press drift Article no.: 61229013000 200311-01 Engine blocking screw Article no.: 61229015000 200312-01 Pressure bell Article no.: 61229016000 200313-01...
  • Page 202 SPECIAL TOOLS Arms for extractor 78029033100 Article no.: 61229017000 200314-01 Pressure piece Article no.: 61229018000 200315-01 Extractor Article no.: 61229020000 200316-01 Release device for timing chain tensioner Article no.: 61229021000 200317-01 Hex key bit Article no.: 61229025000 200318-01...
  • Page 203 SPECIAL TOOLS Press drift/press sleeve Article no.: 61229044000 200319-01 Press sleeve Article no.: 61229045000 200320-01 Frame support Article no.: 61229050000 400490-01 Centering pin Article no.: 61229051000 400491-01 Floor jack attachment Article no.: 61229055000 400184-01...
  • Page 204 SPECIAL TOOLS Piston pin lock ring insert Article no.: 75029035000 400160-01 Spark plug wrench Article no.: 75029172000 400170-01 Extractor Article no.: 78029033100 500166-01 Valve spring mounting device Article no.: 78029060000 500165-01...

  • Page 205: Standards

    STANDARDS STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 206: Index

    INDEX removing ....... . . 49 INDEX Blank time of the LAP button LAP BLANK T Accessories .
  • Page 207 INDEX front camshafts, removing ..... 81 piston ring end gap, checking ....104 front cylinder head, removing .
  • Page 208 INDEX Fuel tank Oil screen installing ....... . . 33 cleaning .
  • Page 209 INDEX removing ....... . . 36 Spare parts ........6 Starting .
  • Page 210 *3206057en* 3206057en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

1190 rc8 aus/uk 20081190 rc8 fr 20081190 rc8 jp 2008

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