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KTM RC 8C 2022 Owner's Manual
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KTM RC 8C 2022 Owner's Manual

KTM RC 8C 2022 Owner's Manual

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OWNER'S MANUAL
2022
RC 8C
Art. no. 3214552en

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Summary of Contents for KTM RC 8C 2022

  • Page 1 OWNER'S MANUAL 2022 RC 8C Art. no. 3214552en...
  • 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 COMBINATION INSTRUMENT ..... 19 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Display ........... 19 Symbols used ........5 Throttle response ......20 Formats used........5 Engine braking effect ....... 20 SAFETY ADVICE..........6 Service hour counter ......20 Use definition –...
  • Page 5 TABLE OF CONTENTS 12.6 Adjusting the high-speed 13.34 Checking the chain, rear sprocket, compression damping of the shock and engine sprocket ......64 absorber.......... 39 13.35 Removing the main silencer ....65 12.7 Adjusting the low-speed 13.36 Installing the main silencer....65 compression damping of the shock 13.37 Removing the fuel tank ....
  • Page 6 TABLE OF CONTENTS 17.5 Filling/bleeding the cooling 29 LIST OF ABBREVIATIONS......142 system ........98 30 LIST OF SYMBOLS........143 17.6 Changing the coolant......99 30.1 Red symbols........143 18 TUNING THE ENGINE....... 101 30.2 Yellow and orange symbols....143 18.1 Throttle response ......

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary 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 and 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) S04919-10 Clutch lever ( p. 13) Fuel tank filler cap Shift lever ( p. 17)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04920-10 Tail light ( p. 14) Throttle response ( p. 14) Engine braking effect ( p. 15) Pit limiter ( p. 15) Start button ( p. 14) Emergency OFF switch ( 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. S04925-10 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. S04928-10 6.10 Pit limiter The button for pit limiter is fitted on the left of the handlebar. S04928-11 6.11 Indicator lamps overview S04935-10 The indicator lamps offer additional information about the operating state of the motorcycle.

  • Page 18: Steering Damper

    (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: Closing The Fuel Tank Filler Cap

    CONTROLS 6 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 20: Foot Brake Lever

    6 CONTROLS The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. S04930-10 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10...

  • Page 21: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Display S04952-10 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. S04938-10 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: Ergonomics 8

    ERGONOMICS 8 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. S04948-10 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 24: Adjusting The Basic Position Of The Clutch Lever

    8 ERGONOMICS – 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 25: Setting The Step Plate Of The Foot Brake Lever

    ERGONOMICS 8 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 26: Setting The Shift Lever Stub

    8 ERGONOMICS 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 27: Adjusting The Steering Damper

    ERGONOMICS 8 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 28: Preparing For Use

    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 29: Running In The Engine

    PREPARING FOR USE 9 – Adjust basic position of the hand brake lever. ( p. 22) – Check the free travel of the foot brake lever. ( p. 80) – Adjust the basic position of the shift lever. p. 23) –...

  • Page 30: 10 Riding Instructions

    10 RIDING INSTRUCTIONS 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 31: Starting Off

    RIDING INSTRUCTIONS 10 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 32 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 33: 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 34: Stopping, Parking

    10 RIDING INSTRUCTIONS Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. – If possible finish braking before going into a bend. – Always finish braking before you go into a bend. Shift down to a lower gear appropriate to your speed. –...

  • Page 35: Transporting

    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.)
  • Page 36 10 RIDING INSTRUCTIONS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the fuel tank filler cap. ( p.

  • 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. 41) 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 Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 43: Service Work On The Chassis 13

    SERVICE WORK ON THE CHASSIS 13 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 44: Taking The Motorcycle Off The Front Lifting Gear

    13 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Position the lifting gear. Front wheel work stand, small (61129965000) 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 45: Taking The Motorcycle Off The Large Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13 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 46: Installing The Fork Legs

    13 SERVICE WORK ON THE CHASSIS – 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 47 SERVICE WORK ON THE CHASSIS 13 Guideline Screw, handlebar 15 Nm (11.1 lbf ft) stub clamp on fork tube – Repeat the operation on the right side. – Position the brake caliper with the spacers. Mount and tighten screws on both sides. Guideline Screw, front M10x1.25...

  • Page 48: Removing The Lower Triple Clamp

    13 SERVICE WORK ON THE CHASSIS 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 49: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 13 13.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 138) – Position protective ring with the spacer ring. –...
  • Page 50 13 SERVICE WORK ON THE CHASSIS – 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 51: 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 52: Adjusting The Steering Head Bearing Play

    13 SERVICE WORK ON THE CHASSIS – Check the steering head bearing and adjust if neces- sary. Finishing work – Remove the work stand. – Fit the front spoiler. p. 54) 13.12 Adjusting the steering head bearing play Preparatory work –...

  • Page 53: Adjusting The Fork Offset

    SERVICE WORK ON THE CHASSIS 13 13.14 Adjusting the fork offset Preparatory work – Use a suitable work stand. – Remove the lower triple clamp. p. 46) 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 54: Removing The Shock Absorber

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

  • Page 55: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 13 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) Loctite ® 243™ shock absorber S05019-11 –...

  • Page 56: Installing The Front Fender

    13 SERVICE WORK ON THE CHASSIS 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 57: Removing The Tail Section

    SERVICE WORK ON THE CHASSIS 13 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 58: Removing The Trim Along With The Front

    13 SERVICE WORK ON THE CHASSIS 13.23 Removing the trim along with the front Preparatory work – Remove the front spoiler. p. 54) 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 59: Taking Off The Air Filter Box

    SERVICE WORK ON THE CHASSIS 13 13.25 Taking off the air filter box Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 41) Main work – Remove screw and quick release on both sides. – Lift the air filter box cover and pull it off toward the rear. S05021-10 –...

  • Page 60: Mounting The Air Filter Box

    13 SERVICE WORK ON THE CHASSIS – Disconnect housing vent hose and intake air temperature sensor – Take off the air filter box base. S05023-10 13.26 Mounting the air filter box Main work – Connect intake air temperature sensor – Attach housing breather hose –...

  • Page 61: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 13 – Hook air filter box cover at the front under the steering damper and lower it at the rear. – Mount and tighten screw and quick release on both sides. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05021-11 Finishing work...

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

    13 SERVICE WORK ON THE CHASSIS – Unlock quick releases – Remove air filter with air filter support. – Remove air filter from air filter support. S05024-10 13.28 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 63: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 13 – Position air filter and lock quick releases The air filter is correctly positioned. Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage. S05024-11 –...

  • Page 64: Checking The Chain Tension

    13 SERVICE WORK ON THE CHASSIS 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 The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 65: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 13 – Remove the rear of the motorcycle from the lifting gear. p. 41) 13.33 Adjusting 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.

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

    13 SERVICE WORK ON THE CHASSIS 13.34 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 41) Main work – Shift the transmission into neutral. – Check the rear sprocket and the engine sprocket for wear. »...

  • Page 67: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 13 13.35 Removing the main silencer – Remove springs Spring hook (50305017000C1) – Remove fitting – Take off the main silencer. S05030-10 13.36 Installing the main silencer – Position the main silencer. – Mount and tighten fitting Guideline Screw, main silencer 18 Nm (13.3 lbf ft)
  • Page 68 13 SERVICE WORK ON THE CHASSIS 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 69: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 13 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 70: Checking The Frame

    13 SERVICE WORK ON THE CHASSIS – 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 71: Checking The Link Fork

    – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. D05196-10 13.41 Checking the clutch lever play Note Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.

  • Page 72: 14 Brake System

    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 73: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – 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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 74: Checking The Front Brake Linings

    Checking the front brake linings 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 75: 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 76 14 BRAKE SYSTEM – Remove locking wire S05038-10 – Remove screw and move the brake fluid reservoir to a hori- zontal position. – Take off screw cap with the membrane and the shim. S05036-11 – Remove screws and take off the brake caliper. –...

  • Page 77: Checking The Rear Brake Fluid Level

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

  • Page 78: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – 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.) – Position the vehicle vertically.

  • Page 79: Checking The Rear Brake Linings

    Checking the rear brake linings 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 80: 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 81 BRAKE SYSTEM 14 – Position the vehicle vertically. – Take off screw cap with the washer and membrane. S05042-11 – Remove locking wire – Remove screws – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract some if necessary.

  • Page 82: Adjusting The Response Of The Front Brake Pump

    14 BRAKE SYSTEM – Mount and tighten screw cover with the shim and the membrane. Info Use water to immediately clean up any brake fluid that has overflowed or spilled. S05042-11 14.10 Adjusting the response of the front brake pump –...

  • Page 83: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 14 14.12 Adjusting 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 84: 15 Wheels, Tires

    15 WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 41) – Lift the motorcycle with the front lifting gear. ( p. 41) – Remove the front fender. ( p.

  • Page 85: Removing The Rear Wheel

    WHEELS, TIRES 15 – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. – Take the motorcycle off the front lifting gear. ( p. 42) –...
  • Page 86 15 WHEELS, TIRES Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel. – Actuate the foot brake several times before going on a ride until you can feel a firm pressure point. Main work –...

  • 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

    15 WHEELS, TIRES 15.6 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life. – Remove the protection cap. – Check tire pressure when the tires are warm. Tire pressure (warm) front: 75 …...

  • 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 driven. – 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 – Place the 12 V battery into the battery compartment with the terminals facing to the left. 12 V battery (LTM14-B) ( p. 117) – 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 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 35 mm (1.38 in) Coolant level below the upper edge of filler neck » 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.

  • Page 99: Draining The Coolant

    COOLING SYSTEM 17 Finishing work – Install the trim along with the front. p. 56) – Fit the front spoiler. p. 54) 17.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
  • Page 100 17 COOLING SYSTEM 17.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...

  • Page 101: Changing The Coolant

    COOLING SYSTEM 17 17.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very 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 102 17 COOLING SYSTEM Condition Storage Coolant 1.6 l Coolant (1.7 qt.) p. 136) – Completely fill the radiator with coolant and close it with radia- tor cap Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 103: Tuning The Engine 18

    TUNING THE ENGINE 18 18.1 Throttle response Possible states Sun symbol – Extremely direct response • Rain symbol – 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: Adjusting The Basic Position Of The Shift Lever

    18 TUNING THE ENGINE 18.4 Adjusting the basic position of the shift lever – Loosen nut while holding stud Info has an LH thread. – Loosen nut while holding stud – Turn stud to adjust the shift lever. Info S04958-10 The range of adjustment is limited.

  • Page 105: Service Work On The Engine 19

    SERVICE WORK ON THE ENGINE 19 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 106 19 SERVICE WORK ON THE ENGINE – 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 107: Adding Engine Oil

    Engine oil (SAE 10W/50) ( p. 137) 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 108 19 SERVICE WORK ON THE ENGINE 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 109: Cleaning, Care 20

    CLEANING, CARE 20 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 110 20 CLEANING, CARE Perfect finish and high gloss polish for paints ( p. 138) 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.

  • Page 111: Storage 21

    – 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. 41) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 112: Preparing For Use After Storage

    21 STORAGE 21.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 42) – Install the 12-V battery. p. 89) – Change the coolant. ( p. 99) – Check the coolant level. ( p.

  • Page 113: Troubleshooting 22

    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 114 22 TROUBLESHOOTING Faults Possible cause Action – 12-V battery discharged The 12-V battery is not being Check the charging voltage. charged by the alternator – Check the open-circuit current. – The combination instrument Fuse 1 or 2 blown Change the fuse of individual power shows nothing on the display consumers.

  • Page 115: Technical Data 23

    TECHNICAL DATA 23 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 116: Engine Tightening Torques

    23 TECHNICAL DATA 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 117 TECHNICAL DATA 23 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) Loctite ®...

  • Page 118: Capacities

    23 TECHNICAL DATA 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 119: Chassis

    TECHNICAL DATA 23 23.4 Chassis Frame Lattice frame of steel tubes, powder-coated WP Suspension APEX PRO 7543 Fork WP SuspensionAPEX PRO 7746 Shock absorber Brake system front Disc brake with 4-piston brake caliper rear Disc brake with single-pot brake caliper, floating Suspension travel front 120 mm (4.72 in)

  • Page 120: Tires

    180/60 R 17 R TL Pirelli Diablo Superbike Pirelli Diablo Superbike The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: KTM.COM 23.7 Fork Fork article number 05.99.2P.01 WP Suspension APEX PRO 7543...

  • Page 121: Chassis Tightening Torques

    TECHNICAL DATA 23 Weight of rider: 75 … 85 kg (165 … 187 lb.) 84 N/mm (480 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 86 N/mm (491 lb/in) Weight of rider: 95 … 105 kg (209 … 231 lb.) 88 N/mm (502 lb/in) Spring length 130 mm (5.12 in)
  • Page 122 23 TECHNICAL DATA Screw, rear brake caliper 20 Nm (14.8 lbf ft) Long-life grease ( p. 138) Screw, rear brake disc 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, shift rod 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, shift shaft support on 20 Nm (14.8 lbf ft) Loctite...
  • Page 123 TECHNICAL DATA 23...

  • Page 124: 24 Wiring Diagram

    24 WIRING DIAGRAM 24.1 Page 1 of 7 Y01464-01...
  • Page 125 WIRING DIAGRAM 24 Components: Engine control unit 12 V battery Alternator Starter relay with main fuse Start auxiliary relay Electric starter system Voltage regulator...
  • Page 126 24 WIRING DIAGRAM 24.2 Page 2 of 7 Y01465-01...
  • Page 127 WIRING DIAGRAM 24 Components: Engine control unit Fuse Fuse Fuse Power relay Fuel pump relay Fuel pump Main switch Emergency OFF switch, start button...
  • Page 128 24 WIRING DIAGRAM 24.3 Page 3 of 7 Y01466-01...
  • Page 129 WIRING DIAGRAM 24 Components: Engine control unit Immobilizer control unit Fuse CAN bus terminating resistor Antenna of the immobilizer control unit X293 Accessories circuit - X294 Accessories circuit + X295 Diagnostics connector...
  • Page 130 24 WIRING DIAGRAM 24.4 Page 4 of 7 Y01467-01...
  • Page 131 WIRING DIAGRAM 24 Components: Engine control unit Tilt sensor Throttle grip Left injection valve Right injection valve Throttle valve actuator Left ignition coil Right ignition coil...
  • Page 132 24 WIRING DIAGRAM 24.5 Page 5 of 7 Y01468-01...
  • Page 133 WIRING DIAGRAM 24 Components: Engine control unit Coolant temperature sensor Crankshaft speed sensor Clutch switch Lambda sensor cylinder 1, sensor 1 Lambda sensor cylinder 2, sensor 1 Wheel speed sensor...
  • Page 134 24 WIRING DIAGRAM 24.6 Page 6 of 7 Y01469-01...
  • Page 135 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 136 24 WIRING DIAGRAM 24.7 Page 7 of 7 Y01470-01...
  • Page 137 WIRING DIAGRAM 24 Components: Oil pressure sensor Combination instrument Right combination switch Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...

  • Page 138: 25 Substances

    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 139 SUBSTANCES 25 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA2 ( p. 140) – SAE ( p. 140) (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 140: 26 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 141 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 142: 27 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 143: Index Of Special Terms 28

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

  • Page 144: Filling/Bleeding The Cooling

    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 145: 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 146: Index

    INDEX Chain tension INDEX adjusting ......63 checking ......62 12 V battery installing .
  • Page 147 INDEX spring preload, adjusting ....38 Fork article number ..... . 12 Main fuse Fork legs changing .
  • Page 148 INDEX Shift lever ......17 Tire condition basic position, adjusting ... 23, 102 checking .
  • Page 149 *3214552en* 3214552en 08/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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