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KTM RC 8C 2023 Owner's Manual
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KTM RC 8C 2023 Owner's Manual

KTM RC 8C 2023 Owner's Manual

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OWNER'S MANUAL
2023
RC 8C
Art. no. 3214768en

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Summary of Contents for KTM RC 8C 2023

  • Page 1 OWNER'S MANUAL 2023 RC 8C Art. no. 3214768en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.18 Foot brake lever ....... 18 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 COMBINATION INSTRUMENT ..... 19 Symbols used ........5 Formats used........5 Display ........... 19 Throttle response ......20 SAFETY ADVICE..........6 Engine braking effect ....... 20 Use definition –...
  • Page 5 TABLE OF CONTENTS 12.5 Compression damping of the shock 13.32 Checking the chain tension ....63 absorber.......... 39 13.33 Adjusting the chain tension....63 12.6 Adjusting the high-speed 13.34 Checking the chain, rear sprocket, compression damping of the shock and engine sprocket ......64 absorber..........
  • Page 6 TABLE OF CONTENTS 17.2 Checking the antifreeze and coolant 25 SUBSTANCES .......... 138 level ..........95 26 AUXILIARY SUBSTANCES ......140 17.3 Checking the coolant level ....96 17.4 Draining the coolant ..... 97 27 STANDARDS ..........142 17.5 Filling/bleeding the cooling 28 INDEX OF SPECIAL TERMS .......

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. Info Only operate this vehicle in closed-off areas remote from public road traffic. Misuse The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended.

  • Page 9: Tampering Warning

    Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

  • Page 10: Work Rules

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S05634-10 Clutch lever ( p. 13) Fuel tank filler cap Shift lever ( p. 18)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05635-10 Tail light ( p. 14) Throttle response ( p. 14) Engine braking effect ( p. 15) Pit limiter ( p. 15) Anti-wheelie mode ( p. 15) Slip adjuster ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the frame. S04924-10 Engine number Engine number is embossed on the left side of the engine above the engine sprocket. S03966-10 Fork article number The fork article number is stamped on the inside of the axle clamp.

  • Page 15: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. S05618-10 Hand brake lever The front brake is engaged using the hand brake lever. The hand brake lever is located on the right side of the han- dlebar.

  • Page 16: Emergency Off Switch

    6 CONTROLS Emergency OFF switch The ignition switch is fitted on the right side of the handlebar. Info To maintain the GPS reception of the combination instru- ment, it is recommended that you switch the ignition on and off using the emergency OFF switch ( p.

  • Page 17: Engine Braking Effect

    CONTROLS 6 Engine braking effect The button for engine braking effect is fitted on the left of the handlebar. S05620-11 6.10 Pit limiter The button for pit limiter is fitted on the left of the handlebar. S05620-12 6.11 Slip adjuster The button for slip adjuster is located on the left of the han- dlebar.

  • Page 18: Indicator Lamps Overview

    (taking care not to endanger yourself or other road users in the process) and contact an authorized KTM workshop. The oil pressure warning lamp always lights up as long as the engine is not running. If the engine is run- ning and the oil pressure warning lamp lights up, stop immediately (taking care not to endanger yourself or other road users in the process) and switch off the engine.

  • Page 19: Steering Damper

    CONTROLS 6 The anti-wheelie mode indicator lamp lights up white and crossed out – The anti-wheelie mode is deactivated. 6.14 Steering damper Steering damper suppresses shocks to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel.

  • Page 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS 6.16 Closing the fuel tank filler cap – Position the fuel tank cover. Guideline The fuel tank cover must not protrude. – Turn fuel tank quick release clockwise. S04932-10 6.17 Shift lever Shift lever is located in front of the left footrest. S04953-10 The gear positions can be seen in the figure.

  • Page 21: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Display S05617-10 Info The figure shows the start screen of the combination instrument. A detailed description of the combination instrument can be found at www.aim‑sportline.com. Gear display Shift warning light Tachometer Lap time Coolant temperature warning lamp Lights up blue <...

  • Page 22: Throttle Response

    7 COMBINATION INSTRUMENT Throttle response The throttle response setting is shown in section of the dis- play. In section the pre-selection for the throttle response is dis- played. S05623-10 Engine braking effect The engine braking effect setting is shown in section In section , the pre-selection for the engine braking effect is displayed.

  • Page 23: Service Hour Counter

    COMBINATION INSTRUMENT 7 Service hour counter – Press button MENU briefly. The main menu opens. – Press one of the arrow buttons on the left side repeatedly until menu item Counters is selected. – Press button OK. The service hour counter and trip odometer are displayed. –...

  • Page 24: Ergonomics

    8 ERGONOMICS Handlebar position The width and angle of the handlebar stubs can be adjusted vari- ably. Info The handlebar stub position must be identical on the left and right of the vehicle. S05624-10 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued.

  • Page 25: Adjusting The Basic Position Of The Clutch Lever

    ERGONOMICS 8 – Adjust the handlebar angle. – Loosen screws . Adjust the angle and height of the handle- bar. Guideline Standard distance between 10 mm upper triple clamp and han- dlebar clamp Mount the left and right handlebar in the same position. –...

  • Page 26: Setting The Step Plate Of The Foot Brake Lever

    8 ERGONOMICS Setting the step plate of the foot brake lever – Remove screw – Screw in foot brake lever stub at the desired position. Guideline Standard Stub in front position Info The foot brake lever stub can be set to two different positions.

  • Page 27: Setting The Shift Lever Stub

    ERGONOMICS 8 Setting the shift lever stub – Remove screw – Screw in the shift lever stub at the desired position. Guideline Standard Stub in rear position Info The shift lever stub can be set to three different posi- tions. The shift lever stud is set at the factory and does not S04959-10 need to be changed.

  • Page 28: Adjusting The Steering Damper

    8 ERGONOMICS Guideline Screw, main silencer 18 Nm (13.3 lbf ft) – Attach retainer springs of the main silencer. – Unscrew screws and remove screw – Position the footrest at one of the three possible positions. Info The adjustable footrest allows up to three footrest posi- tions.

  • Page 29: Preparing For Use 9

    Info When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. The delivery certificate is transferred upon vehicle handover. – Read the entire Owner's Manual before riding for the first time.

  • Page 30: Running In The Engine

    9 PREPARING FOR USE – Adjust basic position of the hand brake lever. ( p. 23) – Check the free travel of the foot brake lever. ( p. 82) – Adjust the basic position of the shift lever. p. 24) –...

  • Page 31: Riding Instructions 10

    RIDING INSTRUCTIONS 10 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 32: Starting Off

    10 RIDING INSTRUCTIONS Main work – Put the emergency OFF switch to the pushed-in position. – Switch on power supply by setting the tilt switch into the posi- tion After you switch on the ignition, you can hear the fuel pump working for about two seconds.
  • Page 33 Info If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.).

  • Page 34: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 35: Stopping, Parking

    RIDING INSTRUCTIONS 10 – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not over- rev the engine when doing so. This means that significantly less braking is required and the brake system does not overheat.

  • Page 36: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 37: Service Schedule 11

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
  • Page 38 Final check: Check the vehicle for operating safety and take for a test ride. ● ● ● ● ● ● ● Read out the fault memory after the test ride using the KTM diagnostics tool. ● ● ● ● ● ● ●...

  • Page 39: Tuning The Chassis 12

    TUNING THE CHASSIS 12 12.1 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info The adjusting screw is located at the upper end of the left fork leg.

  • Page 40: Adjusting The Spring Preload Of The Fork

    12 TUNING THE CHASSIS 12.3 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 42) Main work – Turn adjusting screws counterclockwise all the way. Guideline Do not place a load on the fork. Info Adjusting screws are located at the top end of the...

  • Page 41: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.

  • Page 42: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.
  • Page 43 TUNING THE CHASSIS 12 Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds.

  • Page 44: 13 Service Work On The Chassis

    13 SERVICE WORK ON THE CHASSIS 13.1 Raising the motorcycle with rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Insert the adapter in the rear lifting gear. Retaining adapter (61029955144) Rear wheel work stand (69329955000) Info...

  • Page 45: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13 Main work – Move the handlebar to the straight-ahead position. Position the lifting gear. Front wheel work stand, small (61129965100) Info Always raise the motorcycle at the rear first. – Lift the motorcycle at the front. S04998-01 13.4 Taking the motorcycle off the front lifting gear...

  • Page 46: Taking The Motorcycle Off The Large Front Lifting Gear

    13 SERVICE WORK ON THE CHASSIS 13.6 Taking the motorcycle off the large front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Main work –...

  • Page 47: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 13 – Remove screws from both sides and take off the brake calipers. – Hang the brake calipers to the side. Info Do not actuate the hand brake lever when the front wheel is removed. Cover the components to protect them against damage.
  • Page 48 13 SERVICE WORK ON THE CHASSIS Guideline Screw, handle- M6x30 10 Nm (7.4 lbf ft) bar stub clamp Long-life grease on fork tube p. 140) – Repeat the operation on the right side. – Position the brake caliper with the spacers. Mount and tighten screws on both sides.

  • Page 49: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 13 13.9 Removing the lower triple clamp Condition Front wheel removed. The fork legs have been removed. Preparatory work – Use a suitable work stand. Main work – Take brake line out of the holders and hang to the side of the brake calipers.

  • Page 50: Installing The Lower Triple Clamp

    13 SERVICE WORK ON THE CHASSIS 13.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 140) – Position protective ring with the spacer ring. –...
  • Page 51 SERVICE WORK ON THE CHASSIS 13 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screws on both sides. Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp – Position the handlebar stub and tighten screws on both sides.

  • Page 52: Checking The Steering Head Bearing Play

    Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Preparatory work – Remove the front spoiler.

  • Page 53: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 13 – Check the steering head bearing and adjust if neces- sary. Finishing work – Remove the work stand. – Fit the front spoiler. p. 55) 13.12 Adjusting the steering head bearing play Preparatory work –...

  • Page 54: Adjusting The Fork Offset

    13 SERVICE WORK ON THE CHASSIS 13.14 Adjusting the fork offset Preparatory work – Use a suitable work stand. – Remove the lower triple clamp. p. 47) Main work – Remove screws and screw S05015-10 – Remove screws S05016-10 – Screw screw into the lower thread until the steering stem is loosened.

  • Page 55: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 13 – Position the work stand support. – Mount and tighten screws Guideline Screws, work 15 Nm (11.1 lbf ft) stand adapter, Loctite ® 243™ front – Mount and tighten screws Guideline S05015-10 Screws, work 15 Nm (11.1 lbf ft) stand adapter, Loctite...

  • Page 56: Installing The Shock Absorber

    13 SERVICE WORK ON THE CHASSIS 13.16 Installing the shock absorber – Carefully position the shock absorber into the vehicle from the bottom. – Mount and tighten screw Guideline Screw, top M10x1.25 45 Nm (33.2 lbf ft) shock absorber Loctite ®...

  • Page 57: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 13 13.18 Installing the front fender – Position the front fender. Mount and tighten quick releases The fender engages in the holding lugs. S04951-10 13.19 Removing the front spoiler – Unlock quick releases on both sides. –...

  • Page 58: Removing The Tail Section

    13 SERVICE WORK ON THE CHASSIS 13.21 Removing the tail section – Remove screws – Pull the tail section toward the rear to remove. S04999-10 13.22 Installing the tail section – Position the tail section. – Mount and tighten screws Guideline Remaining screws, 5 Nm (3.7 lbf ft)

  • Page 59: Removing The Trim Along With The Front

    SERVICE WORK ON THE CHASSIS 13 13.23 Removing the trim along with the front Preparatory work – Remove the front spoiler. p. 55) Main work – Unlock quick releases on both sides. – Unlock quick releases – Remove the trim toward the front. S05001-10 13.24 Installing the trim along with the front...

  • Page 60: Taking Off The Air Filter Box

    13 SERVICE WORK ON THE CHASSIS 13.25 Taking off the air filter box Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 42) – Remove the front spoiler. p. 55) – Remove the trim along with the front. p.

  • Page 61: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 13 – Mount quick release – Mount intake flanges and locking wire – Position the air filter and close quick releases S05640-10 Finishing work – Install the trim along with the front. p. 57) – Fit the front spoiler.

  • Page 62: Cleaning The Air Filter And Air Filter Box

    13 SERVICE WORK ON THE CHASSIS – Remove screw and quick release on both sides. – Lift the air filter box cover and pull it off toward the rear. S05021-10 – Unlock quick releases – Remove air filter with air filter support. –...

  • Page 63: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 13 Oil for foam air filter ( p. 140) – Clean the air filter box. – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 61) 13.29 Installing the air filter –...

  • Page 64: Checking For Chain Dirt Accumulation

    13 SERVICE WORK ON THE CHASSIS 13.30 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 62) 400678-01 13.31 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 65: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 13 13.32 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 66: Checking The Chain, Rear Sprocket, And Engine Sprocket

    13 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 30 … 35 mm (1.18 … 1.38 in) Turn adjusting screws on the left and right so that chain adjusters on the left and right have the same...

  • Page 67: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 13 – Pull on the lower chain section with specified weight Guideline Weight, chain wear measure- 15 kg (33 lb.) ment – Measure distance of 20 chain rollers in the lower chain section. Info Chains do not always wear evenly. Repeat this measure- ment at different chain positions.

  • Page 68: Installing The Main Silencer

    13 SERVICE WORK ON THE CHASSIS 13.36 Installing the main silencer – Position the main silencer. – Mount and tighten fitting Guideline Screw, main silencer 18 Nm (13.3 lbf ft) – Mount springs Spring hook (50305017000C1) S05030-11 13.37 Removing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 69 SERVICE WORK ON THE CHASSIS 13 Main work – Remove fittings and hang the adjuster to the side. Info Protect the components against damage by covering them. S05018-12 – Remove the cable ties along the fuel line. – Unplug connector of the fuel pump.

  • Page 70: Installing The Fuel Tank

    13 SERVICE WORK ON THE CHASSIS 13.38 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 71: Checking The Frame

    SERVICE WORK ON THE CHASSIS 13 – Mount the cable ties along the fuel line at the marked posi- tions. – Plug in connector of the fuel pump. S05031-11 – Position the adjusting lever. – Mount and tighten fitting Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis...

  • Page 72: Checking The Link Fork

    13 SERVICE WORK ON THE CHASSIS 13.40 Checking the link fork – Check the link fork for damage, cracks, and deformation. » If the link fork shows signs of damage, cracks, or deforma- tion: – Change the link fork. Guideline Repairs on the link fork are not permitted.

  • Page 73: Brake System 14

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 74: Adding Front Brake Fluid

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho-...

  • Page 75: Checking That The Brake Linings Of The Front Brake Are Secured

    Checking that the brake linings of the front brake are secured Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 76: Changing The Brake Linings Of The Front Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 77 BRAKE SYSTEM 14 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 78 14 BRAKE SYSTEM – Remove brake linings – Clean the brake caliper. – Position new brake linings Info Ensure that the spring is correctly seated. Always change the brake linings in pairs. S05040-10 – Position the brake caliper with the spacers. –...

  • Page 79: Checking The Rear Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your autho- rized KTM workshop will be glad to help.)

  • Page 80: Checking That The Brake Linings Of The Rear Brake Are Secured

    Checking that the brake linings of the rear brake are secured Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 81: Changing The Rear Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 82: Remove Screws

    14 BRAKE SYSTEM Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 83: Adjusting The Response Of The Front Brake Pump

    BRAKE SYSTEM 14 – Position the brake caliper. – Mount and tighten screws Guideline Screw, rear M8x20 25 Nm (18.4 lbf ft) brake caliper Long-life grease p. 140) – Mount locking wire Wire twister forceps (00029015100) S05044-10 Securing wire (54812016000) –...

  • Page 84: Checking The Free Travel Of The Foot Brake Lever

    14 BRAKE SYSTEM 14.11 Checking the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 85: Wheels, Tires 15

    WHEELS, TIRES 15 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 42) – Lift the motorcycle with the front lifting gear. ( p. 42) – Remove the front fender. ( p.

  • Page 86: Removing The Rear Wheel

    15 WHEELS, TIRES – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork shoe M8x50 10 Nm (7.4 lbf ft) Long-life grease p. 140) Finishing work – Install the front fender.

  • Page 87: Checking The Tire Condition

    Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.

  • Page 88: Checking Tire Pressure

    Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index. Info The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 89: Electrical System 16

    ELECTRICAL SYSTEM 16 16.1 Switching the tail light on and off – Press and hold the tail light to switch on the tail light. The tail light lights up or flashes. The tail light does not light up. – Charge the tail light. ( p.

  • Page 90: Removing The 12-V Battery

    16 ELECTRICAL SYSTEM 16.3 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is operated. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –...

  • Page 91: Installing The 12-V Battery

    ELECTRICAL SYSTEM 16 16.4 Installing the 12-V battery Main work – Insert the 12 V battery into the battery compartment with the terminals facing to the left. 12 V battery (LTM14-B) ( p. 118) – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm...

  • Page 92: Charging The 12-V Battery

    16 ELECTRICAL SYSTEM 16.5 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 93: Changing The Main Fuse

    It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures. These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...

  • Page 94: Changing The Fuse Of Individual Power Consumers

    16 ELECTRICAL SYSTEM Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work – Switch off power supply by setting the tilt switch into the posi- tion –...

  • Page 95: Diagnostics Connector

    ELECTRICAL SYSTEM 16 Main work – Open fuse box cover. – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition switch Fuse 2 - 10 A - power relay Fuse 3 - 10 A - fuel pump Fuse 4 - 5 A - ACC2 S05055-10 Info...

  • Page 96: Acc2 Front

    16 ELECTRICAL SYSTEM 16.9 ACC2 front Installation location – Power supplies ACC2 front are located on the right-hand side under the air filter box. S05062-10...

  • Page 97: Cooling System 17

    COOLING SYSTEM 17 17.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 98: Checking The Coolant Level

    17 COOLING SYSTEM » If the coolant level does not match the specified value: – Correct the coolant level. – Mount the radiator cap. Finishing work – Install the trim along with the front. p. 57) – Fit the front spoiler. p.

  • Page 99: Draining The Coolant

    COOLING SYSTEM 17 17.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 100: Changing The Coolant

    17 COOLING SYSTEM Main work – Remove radiator cap – Remove bleeder screw – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immedi- ately. Condition Storage S05058-10 Coolant 1.6 l Coolant (1.7 qt.) p.
  • Page 101 COOLING SYSTEM 17 Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 102 17 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 103: Tuning The Engine

    TUNING THE ENGINE 18 18.1 Throttle response Possible states 1 – Extremely direct response • 2 – Gentle response. • The throttle response can be adjusted with button The throttle response can also be set while riding when the throttle grip is closed.

  • Page 104: Anti-Wheelie Mode

    18 TUNING THE ENGINE 18.4 Anti-wheelie mode Possible states AMW written out – Anti-wheelie mode is activated • AWM crossed out – Anti-wheelie mode is deactivated • Anti-wheelie mode is a vehicle electronics function. Anti-wheelie mode is intended to prevent the front wheel rising when accelerating.
  • Page 105 TUNING THE ENGINE 18 – Tighten nut while holding stud Guideline Nut, shift rod 10 Nm (7.4 lbf ft) – Tighten nut while holding stud Guideline Nut, shift rod M6LH 10 Nm (7.4 lbf ft)

  • Page 106: 19 Service Work On The Engine

    19 SERVICE WORK ON THE ENGINE 19.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 107 SERVICE WORK ON THE ENGINE 19 – Remove locking wire. – Remove oil drain plugs along with the magnets, the O- rings, and the oil screens. S05066-10 – Remove screws . Take off oil filter cover with the O- ring. –...

  • Page 108: Adding Engine Oil

    Engine oil (SAE 10W/50) ( p. 139) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. H01066-10 KTM recommends changing the engine oil where neces- sary. – Mount and tighten filler plug with the O-ring.
  • Page 109 SERVICE WORK ON THE ENGINE 19 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 110: Cleaning, Care

    20 CLEANING, CARE 20.1 Cleaning the motorcycle Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Clean the motorcycle regularly to maintain its value and appearance over a long period. Avoid direct sunshine when cleaning the motorcycle.
  • Page 111 CLEANING, CARE 20 Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p.

  • Page 112: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 42) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 113: Preparing For Use After Storage

    STORAGE 21 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 43) – Install the 12-V battery. p. 89) – Change the coolant. ( p. 98) – Check the coolant level. ( p.

  • Page 114: Troubleshooting

    Join the quick release coupling. joined – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Throttle opened while starting When starting, DO NOT open the throt- tle. – Carry out start procedure. ( p.
  • Page 115 TROUBLESHOOTING 22 Faults Possible cause Action – The combination instrument Fuse 1 or 2 blown Change the fuse of individual power shows nothing on the display consumers. ( p. 92)

  • Page 116: Technical Specifications

    23 TECHNICAL SPECIFICATIONS 23.1 Engine Design 2-cylinder 4-stroke in-line engine, water-cooled Displacement 890 cm³ (54.31 cu in) Stroke 68.8 mm (2.709 in) Bore 90.7 mm (3.571 in) Compression ratio 13.5:1 Idle speed 2,300 ± 50 rpm Control DOHC, 4 valves per cylinder controlled via cam lever, chain drive Valve diameter, intake 37 mm (1.46 in)

  • Page 117: Engine Tightening Torques

    TECHNICAL SPECIFICATIONS 23 23.2 Engine tightening torques EJOTALtracs Plus 60x14 Screw plug, water pump drain hole ® 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, bleeder flange EJOTALtracs ® M6x12 8 Nm (5.9 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Nozzle, engine vent 2 Nm (1.5 lbf ft)
  • Page 118 23 TECHNICAL SPECIFICATIONS Screw, locking lever 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, main shaft bearing support 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil pan M6x30 10 Nm (7.4 lbf ft) Screw, oil pan M6x35 10 Nm (7.4 lbf ft) Screw, oil pump cover 10 Nm (7.4 lbf ft)

  • Page 119: Capacities

    TECHNICAL SPECIFICATIONS 23 Screw, conrod bearing M8x0.75 1st stage 5 Nm (3.7 lbf ft) 2nd stage 20 Nm (14.8 lbf ft) 3rd stage 90° Screw support and thread oiled Spark plug 11 Nm (8.1 lbf ft) Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) Screw plug, bearing support M10x1...

  • Page 120: Fuel

    23 TECHNICAL SPECIFICATIONS 23.3.3 Fuel Total fuel tank capacity, approx. 16 l (4.2 US gal) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 139) 23.4 Chassis Frame Lattice frame of steel tubes, powder-coated WP Suspension APEX PRO 7543 Fork Shock absorber WP SuspensionAPEX PRO 7746...

  • Page 121: Tires

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM 23.7 Fork Fork article number...

  • Page 122: Chassis Tightening Torques

    23 TECHNICAL SPECIFICATIONS Sport 12 clicks Race 6 clicks Spring preload Standard 13 mm (0.51 in) Spring rate Weight of rider: 55 … 65 kg (121 … 143 lb.) 70 N/mm (400 lb/in) Weight of rider: 65 … 75 kg (143 … 165 lb.) 76 N/mm (434 lb/in) Weight of rider: 75 …...
  • Page 123 TECHNICAL SPECIFICATIONS 23 Screw, footrest bracket M8x20 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fork shoe M8x50 10 Nm (7.4 lbf ft) Long-life grease ( p. 140) Screw, fuel tank fastening M8x20 25 Nm (18.4 lbf ft) Loctite ®...
  • Page 124 23 TECHNICAL SPECIFICATIONS Nut, rear wheel spindle M25x1.5 100 Nm (73.8 lbf ft) Long-life grease ( p. 140) Nut, steering head, top M25x1.5 18 Nm (13.3 lbf ft) Screw, front wheel spindle M29x1.5 60 Nm (44.3 lbf ft) Long-life grease ( p.
  • Page 125 TECHNICAL SPECIFICATIONS 23...

  • Page 126: 24 Wiring Diagram

    24 WIRING DIAGRAM 24.1 Page 1 of 7 Y02870-01...
  • Page 127 WIRING DIAGRAM 24 Components: Engine control unit 12-V battery Alternator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator...
  • Page 128 24 WIRING DIAGRAM 24.2 Page 2 of 7 Y02871-01...
  • Page 129 WIRING DIAGRAM 24 Components: Engine control unit Fuse Fuse Fuse Power relay Fuel pump relay Fuel pump Main switch Combination switch, right...
  • Page 130 24 WIRING DIAGRAM 24.3 Page 3 of 7 Y02872-01...
  • Page 131 WIRING DIAGRAM 24 Components: Engine control unit Immobilizer control unit Control unit Front wheel speed sensor Rear wheel speed sensor Inertial measurement unit Fuse Antenna of the immobilizer control unit X295 Diagnostics connector...
  • Page 132 24 WIRING DIAGRAM 24.4 Page 4 of 7 Y02873-01...
  • Page 133 WIRING DIAGRAM 24 Components: Engine control unit Throttle grip Injection valve, cylinder 1 Injection valve, cylinder 2 Throttle valve actuator and throttle valve position sensor Ignition coil, cylinder 1 Ignition coil cylinder 2...
  • Page 134 24 WIRING DIAGRAM 24.5 Page 5 of 7 Y02874-01...
  • Page 135 WIRING DIAGRAM 24 Components: Engine control unit Coolant temperature sensor Crankshaft speed sensor Clutch switch Lambda sensor, cylinder 1 Lambda sensor, cylinder 2...
  • Page 136 24 WIRING DIAGRAM 24.6 Page 6 of 7 Y02875-01...
  • Page 137 WIRING DIAGRAM 24 Components: Engine control unit Intake air temperature sensor Shift shaft sensor Gear position sensor Induction manifold pressure sensor, cylinder 1 and cylinder 2 Knock sensor...
  • Page 138 24 WIRING DIAGRAM 24.7 Page 7 of 7 Y02876-01...
  • Page 139 WIRING DIAGRAM 24 Components: Oil pressure sensor Combination instrument Combination switch, left Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 140: Checking The Antifreeze And Coolant

    25 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 141 SUBSTANCES 25 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA2 ( p. 142) – SAE ( p. 142) (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.

  • Page 142: Auxiliary Substances

    26 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 143 AUXILIARY SUBSTANCES 26 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX ® – Chainlube Road Strong...

  • Page 144: Standards

    27 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 145: Index Of Special Terms

    INDEX OF SPECIAL TERMS 28 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 146: List Of Abbreviations

    29 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 147: List Of Symbols

    LIST OF SYMBOLS 30 30.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The oil pressure warning lamp lights up red – The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine.

  • Page 148: Index

    INDEX Chain INDEX chain dirt accumulation, checking ..62 checking ......64 12 V battery cleaning .
  • Page 149 INDEX setting the step plate ....24 Link fork checking ......70 Footrests adjusting .
  • Page 150 INDEX engine tightening torques ... . . 115 fork ......119 Safe operation .
  • Page 151 *3214768en* 3214768en 22.02.2023 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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