KTM 1190 RC8 R USA Owner's Manual
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KTM 1190 RC8 R USA Owner's Manual

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OWNER'S MANUAL
2012
1190 RC8 R USA
Art. no. 3211786en

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Summary of Contents for KTM 1190 RC8 R USA

  • Page 1 OWNER'S MANUAL 2012 1190 RC8 R USA Art. no. 3211786en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Combination instrument - activation and test ...... 37 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Display ................38 IMPORTANT INFORMATION ........... 8 Info display..............39 Overview of labels............. 12 Indicator lamps ..............40 VIEW OF VEHICLE..............22 Notes/warnings on the combination instrument....
  • Page 6 TABLE OF CONTENTS Fuel reserve display menu, TRIP F RESET ......71 Passenger footrests............106 UNITS menu..............72 Shift lever..............106 Kilometers/miles menu, SET KM/MILES ......74 Foot brake lever.............. 107 Temperature display menu, SET °C/°F ........ 75 Side stand ..............108 Fuel consumption menu (liters), SET FUEL CONS ....
  • Page 7 TABLE OF CONTENTS Adjusting the high-speed compression damping of the Removing the passenger seat........... 167 shock absorber ............... 133 Mounting the passenger seat ........... 167 Adjusting the rebound damping of the shock absorber..134 Checking for chain dirt............ 168 Adjusting the spring preload of the shock absorber ..
  • Page 8 TABLE OF CONTENTS ELECTRICAL SYSTEM ............198 STORAGE ................237 Storage................237 Removing the battery ..........198 Putting into operation after storage ........238 Installing the battery ..........200 TROUBLESHOOTING............239 Recharging the battery ..........201 IMMOBILIZER BLINK CODE..........242 Changing the main fuse ..........

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs done in an authorized KTM-RC8 workshop! There, your motorcycle will be serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    IMPORTANT INFORMATION Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for use on dirt roads. Info The motorcycle is authorized for public road traffic in the homologous version only.
  • Page 11 IMPORTANT INFORMATION Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be glad to advise you. You will find the current KTM PowerParts for your vehicle on the KTM website.
  • Page 12 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and con- flicts.

  • Page 14: Overview Of Labels

    IMPORTANT INFORMATION Overview of labels B00569-10...
  • Page 15 IMPORTANT INFORMATION Information on putting into operation Type label for Canada Type label for the USA Emission control information Noise emission information Chain tension information Information on suspension setting Fuel evaporative system information Information on locking of passenger seat Information on fuel quality/engine electronics mapping Information on putting into operation 600961-01...
  • Page 16 IMPORTANT INFORMATION B00592-01 Type label for Canada 600930-01 Type label for the USA...
  • Page 17 IMPORTANT INFORMATION C00130-01 Emission control information C00128-01 Noise emission information...
  • Page 18 IMPORTANT INFORMATION 600928-01 Chain tension information B00594-01 Information on suspension setting...
  • Page 19 IMPORTANT INFORMATION C00129-01 Fuel evaporative system information Information on locking of passenger seat 100487-10...
  • Page 20 IMPORTANT INFORMATION B00596-01 Information on fuel quality/engine electronics mapping Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.
  • Page 21 If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM...
  • Page 22 Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
  • Page 23 Consumer rights Warranty claims should be submitted to an authorized KTM workshop. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 24: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (vehicle differs slightly from photo) C00127-10...
  • Page 25 VIEW OF VEHICLE Clutch lever ( p. 29) Light switch ( p. 30) Headlight flasher switch ( p. 31) Turn signal switch ( p. 31) Horn button ( p. 32) Filler cap Seat lock ( p. 108) Oil dipstick Side stand ( p.

  • Page 26: View Of Vehicle, Rear Right Side (Vehicle Differs Slightly From Photo)

    VIEW OF VEHICLE View of vehicle, rear right side (vehicle differs slightly from photo) B00567-10...
  • Page 27 VIEW OF VEHICLE Passenger seat Supporting strap ( p. 105) Rear mirror Combination instrument Emergency OFF switch ( p. 32) Electric starter button ( p. 33) Hand brake lever ( p. 29) Vehicle identification number/type label ( p. 26) Shock absorber rebound adjustment Foot brake lever ( p.

  • Page 28: Serial Numbers

    SERIAL NUMBERS Vehicle identification number/type label The vehicle identification number is stamped on the frame behind the steering head on the right. The type label USA is on the frame above the vehicle identification number. The type label for Canada is located on the frame on the left behind the steering head. 100654-10 Engine number The engine number...

  • Page 29: Key Number

    SERIAL NUMBERS Key number The key number Code number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. Use the orange programming key to activate and deactivate the black ignition key. Keep the orange programming key in a safe place: it must only be used for learning and programming functions.

  • Page 30: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring towards the rear. 100657-10 Steering damper part number The steering damper part number is stamped on the top of the steering damper. 100658-10...

  • Page 31: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulic and self-adjusting. 100659-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. 100660-10...

  • Page 32: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. B00568-10 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is in the lower position. In this position, the low beam and tail light are switched on.

  • Page 33: Headlight Flasher Switch

    CONTROLS Headlight flasher switch The headlight flasher switch is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in neutral position Headlight flasher switch pressed – The headlight flasher switch (high beam) is oper- • ated in this position.

  • Page 34: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 100661-12 Emergency OFF switch The emergency OFF switch is installed on the right side of the handlebar.

  • Page 35: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in neutral position pressed – In this position, the electric starter is operated. • Electric starter button 100664-11 Ignition/steering lock 5.10...

  • Page 36: Immobilizer

    The second black ignition key is activated when the vehicle is shipped. Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM RC8 workshop, but they must be activated before use.

  • Page 37: Combination Instrument - Overview

    CONTROLS Combination instrument - overview 5.12 Display ( p. 38) Function buttons Indicator lamps ( p. 40) Info display ( p. 39) 401121-10...

  • Page 38: Combination Instrument - Function Buttons On Handlebar

    CONTROLS Combination instrument - function buttons on handlebar 5.13 The MODE button is fitted on the handlebar, front left. The LAP button is fitted on the handlebar, rear left. MODE button Changes to the next item on the info display in ROAD mode and in RACE mode. LAP button Changes to the next item on the info display in ROAD mode.

  • Page 39: Combination Instrument - Activation And Test

    The speed display counts from 0 to 300 and back. The remaining display segments outside the info display light up briefly. The KTM logo appears in the info display. The display then changes to the last selected mode. 401120-01...

  • Page 40: Display

    CONTROLS Display 5.15 The tachometer displays the engine speed in revolutions per minute (RPM). The red marking marks the over-rev (excessive speed) range of the engine. The gear display shows the engaged gear. Info The engaged gear can also be displayed in the info display. The speed is displayed in kilometers per hour KM/H or in miles per hour MPH.

  • Page 41: Info Display

    CONTROLS Info display 5.16 The info display has two menus. Menu 1 is ROAD mode (standard) for riding on public roads. Menu 2 is RACE mode for riding on race tracks. It allows riders to time laps themselves. If the general warning lamp lights up, the corresponding message is shown periodically in the info display.

  • Page 42: Indicator Lamps

    CONTROLS Indicator lamps 5.17 Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The oil pressure warning lamp lights up red – The oil pressure is too low. The shift warning lights up/flashes red –...

  • Page 43: Notes/Warnings On The Combination Instrument

    CONTROLS Notes/warnings on the combination instrument 5.18 LOW FUEL appears on the info display if the minimum range falls below the specified value. Distance 20 km (12.4 mi) 401123-01 LOW BATTERY appears on the info display if the battery voltage falls below the specified value.
  • Page 44 CONTROLS SERVICE IN xxx KM(MPH) appears on the info display if the distance to the next service falls below the specified value. Distance 500 km (310.7 mi) 401125-01 HIGH TEMP appears on the info display if the coolant temperature rises above the specified value.

  • Page 46: Overview Of Road Mode

    CONTROLS Overview of ROAD mode 5.19 401128-10...

  • Page 47: Distance Menu 1, Odo/Trip 1/Time 1/Avs 1

    CONTROLS Functions in ROAD mode Distance menu 1, ODO/Trip 1/Time 1/Avs 1 Distance menu 2, ODO/Trip 2/Time 2/Avs 2 Gear display menu, ODO/Trip 1/Gear Fuel and external temperature menu, FUEL Mapping menu, ENGINE MAP Next service menu, DISTANCE TO Next Service Distance menu 1, ODO/Trip 1/Time 1/Avs 1 5.20 Condition...
  • Page 48 CONTROLS Press the button No function Press the button No function Press the button The display changes to the SET‑UP menu and the button 3 - 5 seconds. Press the MODE but- The display of Trip 1, Time 1 and Avs 1 is reset ton for 3 - 5 sec- onds.

  • Page 49: Gear Display Menu, Odo/Trip 1/Gear

    CONTROLS The calculation of this value starts with the first speed signal and ends 3 seconds after the last speed signal. Avs 2 shows the average speed and is coupled with Trip 2 and Time 2. Press the button No function Press the button No function Press the button...
  • Page 50 CONTROLS Trip 1 shows the distance covered since the last reset. For example, between two refueling stops. Trip 1 is always running and counts up to 9999.9. Gear shows the gear currently engaged. Press the button No function Press the button No function Press the button The display changes to the SET‑UP menu...

  • Page 51: Fuel And External Temperature Menu, Fuel

    CONTROLS Fuel and external temperature menu, FUEL 5.23 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • ROAD mode Alternative 2 • The ignition is on. • The motorcycle is being ridden. ROAD mode • –...

  • Page 52: Mapping Menu, Engine Map

    CONTROLS Press the MODE but- Next display mode ton briefly. Mapping menu, ENGINE MAP 5.24 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. • The motorcycle is being ridden. •...

  • Page 53: Next Service Menu, Distance To Next Service

    CONTROLS Next service menu, DISTANCE TO Next Service 5.25 Condition • The ignition is on. • The motorcycle is stationary. • ROAD mode – Press the MODE button briefly and repeatedly until DISTANCE TONext Service appears in the info display. DISTANCE TO Next Service shows the distance before the next service is necessary.

  • Page 54: Overview Of Race Mode

    CONTROLS Overview of RACE mode 5.26 401142-10...

  • Page 55: Remaining Laps Menu, Lapstogo

    CONTROLS Functions in RACE mode Remaining laps menu, LAPSTOGO Maximum lap speed menu, TOPSPEED Gear display menu, LastLap/RaceTrip/Gear Fuel and external temperature menu, FUEL Mapping menu, ENGINE MAP Lap times menu, LAP/BESTLAP/LapTime Maximum speed menu, LAP/BESTLAP/TopSpeed Total distance menu in Race mode RACEODO Remaining laps menu, LAPSTOGO 5.27 Condition...

  • Page 56: Maximum Lap Speed Menu, Topspeed

    CONTROLS LastLap shows the lap time of the last lap. ±Last shows the difference between the last lap and the lap before last. ±Best shows the difference between the last lap and the best lap. If the last lap was the fastest, you see behind ±Best: the Best! symbol in the info display. Press the button No function Press the button...
  • Page 57 CONTROLS If an R appears after TOPSPEED, the stopwatch is running in the background. If a P appears after TOPSPEED, the stopwatch in the background is active but waiting for a speed signal. The time is not running. This function is controlled with the LAP button. LastLap shows the maximum speed of the last lap.

  • Page 58: Gear Display Menu, Lastlap/Racetrip/Gear

    CONTROLS Gear display menu, LastLap/RaceTrip/Gear 5.29 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. RACE mode • Alternative 2 • The ignition is on. • The motorcycle is being ridden. • RACE mode 401145-01 – Press the MODE button briefly and repeatedly until LastLap, RaceTrip, and Gear appear in the info display.

  • Page 59: Fuel And External Temperature Menu, Fuel

    CONTROLS Fuel and external temperature menu, FUEL 5.30 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • RACE mode Alternative 2 • The ignition is on. • The motorcycle is being ridden. RACE mode • –...

  • Page 60: Mapping Menu, Engine Map

    CONTROLS Press the MODE but- Next display mode ton briefly. Mapping menu, ENGINE MAP 5.31 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. RACE mode • Alternative 2 • The ignition is on. • The motorcycle is being ridden. •...

  • Page 61: Lap Times Menu, Lap/Bestlap/Laptime

    CONTROLS Lap times menu, LAP/BESTLAP/LapTime 5.32 Condition • The ignition is on. • The motorcycle is stationary. • RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/LapTime appears in the info display. LAP shows the selected lap. BESTLAP shows the number of the lap with the best lap time.

  • Page 62: Maximum Speed Menu, Lap/Bestlap/Topspeed

    CONTROLS Maximum speed menu, LAP/BESTLAP/TopSpeed 5.33 Condition • The ignition is on. • The motorcycle is stationary. • RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in the info display. LAP shows the selected lap. BESTLAP shows the lap in which the highest maximum speed was reached.

  • Page 63: Total Distance In Race Mode Menu, Raceodo

    CONTROLS Total distance in Race mode menu, RACEODO 5.34 Condition • The ignition is on. • The motorcycle is stationary. • RACE mode – Press the MODE button briefly and repeatedly until RACEODO appears at the top of the info display. RACEODO shows the total distance covered in RACE mode.

  • Page 64: Overview Of Set-Up Mode

    CONTROLS Overview of SET‑UP mode 5.35 ODO/Trip 1 ODO/Trip 2 ODO/Trip 1/Gear FUEL ENGINE MAP SHIFT RPMS DISTANCE TO Next Service LAP BLANK TIME CHANGE MODE SET NUM LAPS SET CLOCK LAPSTOGO TRIP F RESET SETTINGS... TOPSPEED ** SET-UP ** BACK...
  • Page 65 CONTROLS Settings in SET‑UP mode Mode menu, CHANGE MODE Time menu, SET CLOCK Settings menu, SETTINGS Units menu, UNITS Additional functions menu, OPTIONS EXIT SETUP menu...

  • Page 66: Set-Up Menu

    CONTROLS SET‑UP menu 5.36 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • ROAD mode Alternative 2 • The ignition is on. • The motorcycle is stationary. RACE mode • – Press the button and the button for 3 - 5 seconds.

  • Page 67: Mode Menu, Change Mode

    CONTROLS Press the MODE but- The menu in front of the arrow is selected ton for 3 - 5 sec- onds. Press the MODE but- The menu in front of the arrow is selected ton briefly. Mode menu, CHANGE MODE 5.37 Condition Alternative 1...

  • Page 68: Time Menu, Set Clock

    CONTROLS Press the MODE but- Open and exit CHANGE MODE ton briefly. Time menu, SET CLOCK 5.38 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. •...

  • Page 69: Settings Menu

    CONTROLS SETTINGS menu 5.39 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • ROAD mode Alternative 2 • The ignition is on. • The motorcycle is stationary. RACE mode • – Press the button and the button for 3 - 5 seconds.

  • Page 70: Shift Warning Lamp Menu, Shift Rpms

    CONTROLS Press the MODE but- The menu in front of the arrow is selected ton briefly. Shift warning lamp menu, SHIFT RPMS 5.40 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 •...

  • Page 71: Lap Button Blank Time, Lap Blank Time Menu

    CONTROLS Press the MODE but- Open and exit SHIFT RPMS or change to the next value ton briefly. LAP button blank time, LAP BLANK TIME menu 5.41 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode •...

  • Page 72: Number Of Laps Menu, Set Num Laps

    CONTROLS Press the MODE but- Open and exit LAP BLANK TIME ton briefly. Number of laps menu, SET NUM LAPS 5.42 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • ROAD mode Alternative 2 • The ignition is on.

  • Page 73: Fuel Reserve Display Menu, Trip F Reset

    CONTROLS Press the MODE but- Open and exit SET NUM LAPS ton briefly. Fuel reserve display menu, TRIP F RESET 5.43 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on.

  • Page 74: Units Menu

    CONTROLS Press the MODE but- Open and exit TRIP F RESET ton for 3 - 5 sec- onds. Press the MODE but- Open and exit TRIP F RESET ton briefly. UNITS menu 5.44 Condition Alternative 1 • The ignition is on. •...
  • Page 75 CONTROLS Press the button No function and the button 3 - 5 seconds. Press the MODE but- The menu in front of the arrow is selected ton for 3 - 5 sec- onds. Press the MODE but- The menu in front of the arrow is selected ton briefly.

  • Page 76: Kilometers/Miles Menu, Set Km/Miles

    CONTROLS Kilometers/miles menu, SET KM/MILES 5.45 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. • The motorcycle is stationary. • RACE mode – Press the button and the button for 3 - 5 seconds.

  • Page 77: Temperature Display Menu, Set °C/°F

    CONTROLS Temperature display menu, SET °C/°F 5.46 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. • The motorcycle is stationary. • RACE mode – Press the button and the button for 3 - 5 seconds.

  • Page 78: Fuel Consumption Menu (Liters), Set Fuel Cons

    CONTROLS Fuel consumption menu (liters), SET FUEL CONS 5.47 Condition • The ignition is on. • The motorcycle is stationary. • The KM/H unit is activated. – Press the button and the button for 3 - 5 seconds. – shows UNITS in the info display. Press the button three times until the symbol –...

  • Page 79: Fuel Consumption Menu (Gallons), Set Gal Us/Uk

    CONTROLS Fuel consumption menu (gallons), SET GAL US/UK 5.48 Condition • The ignition is on. • The motorcycle is stationary. • The MPH unit is activated. – Press the button and the button for 3 - 5 seconds. – shows UNITS in the info display. Press the button three times until the symbol –...

  • Page 80: Additional Functions Menu, Options

    CONTROLS Additional functions menu, OPTIONS 5.49 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. • The motorcycle is stationary. • RACE mode 401158-01 – Press the button and the button for 3 - 5 seconds.

  • Page 81: Quick Shifter Menu, Option Qkshift

    CONTROLS Press the MODE but- The menu in front of the arrow is selected ton briefly. Quick shifter menu, OPTION QKSHIFT 5.50 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 •...

  • Page 82: External Temperature Display Menu, Option Outtemp

    CONTROLS Press the MODE but- Open and exit OPTION QKSHIFT ton briefly. External temperature display menu, OPTION OUTTEMP 5.51 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. •...

  • Page 83: Tire Pressure Monitor Menu, Option Tpms

    CONTROLS Press the MODE but- Open and exit OPTION OUTTEMP ton briefly. Tire pressure monitor menu, OPTION TPMS 5.52 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. ROAD mode • Alternative 2 • The ignition is on. •...
  • Page 84 CONTROLS Press the MODE but- Open and exit OPTION TPMS ton for 3 - 5 sec- onds. Press the MODE but- Open and exit OPTION TPMS ton briefly. Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button...
  • Page 85 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button ton for 3 - 5 sec- ton briefly. 3 - 5 seconds. onds. Remaining laps menu, No function No function The display...
  • Page 86 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button ton for 3 - 5 sec- ton briefly. 3 - 5 seconds. onds. SET‑UP menu The arrow moves up The arrow moves No function The menu in front...
  • Page 87 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button ton for 3 - 5 sec- ton briefly. 3 - 5 seconds. onds. Kilometers/miles menu, Changes the unit Changes the unit No function...
  • Page 88 CONTROLS Table of conditions and menu activation Display Menu can be • • • • • • activated ignition ignition ignition ignition ignition ignition is on. is on. is on. is on. is on. is on. • • • • •...
  • Page 89 CONTROLS Table of conditions and menu activation Display Menu can be • • • • • • activated ignition ignition ignition ignition ignition ignition is on. is on. is on. is on. is on. is on. • • • • •...
  • Page 90 CONTROLS Table of conditions and menu activation Display Menu can be • • • • • • activated ignition ignition ignition ignition ignition ignition is on. is on. is on. is on. is on. is on. • • • • •...
  • Page 91 CONTROLS Table of conditions and menu activation Display Menu can be • • • • • • activated ignition ignition ignition ignition ignition ignition is on. is on. is on. is on. is on. is on. • • • • •...

  • Page 92: Adjusting The Mapping Of The Engine Electronics Engine Map

    CONTROLS Adjusting the mapping of the engine electronics ENGINE MAP 5.53 Note Material damage Incorrect mapping damages the engine. – Adjust the mapping of the engine electronics for the fuel quality currently in use. Condition The ignition is on. The motorcycle is stationary. Condition ROAD mode –...

  • Page 93: Displaying Lap Times

    CONTROLS Displaying lap times 5.54 Condition The ignition is on. The motorcycle is stationary. RACE mode – Press the MODE button briefly and repeatedly until LAP/BESTLAP/LapTime appears in the info display. LAP01 appears on the left of the info display. –...

  • Page 94: Setting Road Or Race Mode

    CONTROLS – Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in the info display. LAP01 appears on the left of the info display. – Press the button The next lap is displayed. – Press the button The previous lap is displayed. –...

  • Page 95: Setting The Clock With Set Clock

    CONTROLS Setting the clock with SET CLOCK 5.57 Condition The ignition is on. The motorcycle is stationary. – Press the button and the button for 3 - 5 seconds. – Press the button once until the symbol shows SET CLOCK in the info display. –...
  • Page 96 CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button twice until the symbol shows SETTINGS in the info display. – Press the MODE button briefly. – Press the MODE button briefly. RPM1 and RPM2 appear on the info display. The engine speed after RPM1 flashes.

  • Page 97: Setting The Blank Time Of The Lap Button Lap Blank Time

    CONTROLS – Press the MODE button briefly. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. – Press the MODE button briefly. Setting the blank time of the LAP button LAP BLANK TIME 5.59 Condition The ignition is on.

  • Page 98: Setting The Number Of Laps Set Num Laps

    CONTROLS – shows BACK... in the info Press the button briefly and repeatedly until the symbol display. – Press the MODE button briefly. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. –...

  • Page 99: Setting The Fuel Reserve Display Trip F Reset

    CONTROLS – shows BACK... in the info Press the button briefly and repeatedly until the symbol display. – Press the MODE button briefly. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. –...

  • Page 100: Setting The Kilometers/Miles Set Km/Miles

    CONTROLS – shows BACK... in the info Press the button briefly and repeatedly until the symbol display. – Press the MODE button briefly. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. –...

  • Page 101: Setting The Temperature Unit Set °C/°F

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the MODE button briefly. The selected unit appears on the left in the display.

  • Page 102: Setting The Unit Of Fuel Consumption (Liters) Set Fuel Cons

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the button once until the symbol shows SET °C/°F in the info display.

  • Page 103: Unit Of Fuel Consumption (Gallons) Set Gal Us/Uk

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the button twice until the symbol shows SET FUEL CONS in the info display.

  • Page 104: Switching The External Temperature Display On/Off

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the button three times until the symbol shows SET GAL US/UK in the info dis- play.

  • Page 105: Opening The Filler Cap

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info display. – Press the MODE button briefly. – Press the button once until the symbol shows OPTION OUTTEMP in the info display.
  • Page 106 CONTROLS 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 immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 107: Closing The Filler Cap

    CONTROLS Closing the filler cap 5.68 Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – When closing the filler cap, ensure that it is closed correctly. Change cloth- ing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.

  • Page 108: Passenger Footrests

    CONTROLS Passenger footrests 5.70 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 100672-01 Shift lever 5.71 The shift lever is mounted on the left of the engine.

  • Page 109: Foot Brake Lever

    CONTROLS The gear positions can be seen in the picture. The neutral or idle position is between the first and second gear. B00559-10 Foot brake lever 5.72 The foot brake lever is in front of the right footrest. The foot brake lever operates the rear brake. 100675-10...

  • Page 110: Side Stand

    CONTROLS Side stand 5.73 The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...

  • Page 111: Helmet Lock

    CONTROLS Helmet lock 5.75 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen. Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.

  • Page 112: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 113: Running The Engine In

    PREPARING FOR USE – Make sure that the pre-delivery inspection work has been carried out exclusively by an authorized KTM-RC8 workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.
  • Page 114 PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 115 PREPARING FOR USE – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible total weight 380 kg (838 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 240 kg (529 lb.)

  • Page 116: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level.

  • Page 117: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 118: Starting Off

    RIDING INSTRUCTIONS – Press the emergency OFF switch into the position – Switch on the ignition by turning the black programming key to the position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds.

  • Page 119: Shifting, Riding

    RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. –...
  • Page 120 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 121 Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM-RC8 workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 122: Braking

    Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking effect caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey. Warning Danger of accidents Failure of brake system. –...

  • Page 123: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. –...

  • Page 124: Refueling

    RIDING INSTRUCTIONS – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. –...
  • Page 125 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM RC8 workshop will be pleased to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 126 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 103) – Fill the fuel tank with fuel up to the lower edge of the fuel filler. Total fuel tank 16.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 127: Service Schedule

    Check that the electrical equipment is functioning properly. • • • • • • • • Read out the trouble code memory using the KTM diagnostics tool. • • • Check the measured service values with the KTM diagnostics tool. • • • •...
  • Page 128 Change the air filter. Clean the air filter box. Check the fuel pressure. • • • Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics • • • tool. Check the CO adjustment with the KTM diagnostics tool.
  • Page 129 Final check: Check the vehicle for roadworthiness and take a test ride. • • • • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • Set the service interval display. • • •...

  • Page 130: Tuning The Chassis

    TUNING THE CHASSIS Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table . You will find the table on the underside of the seat.

  • Page 131: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise to the stop. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping B00572-10...

  • Page 132: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise to the stop. Info The adjustment screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort...

  • Page 133: Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screws clockwise to the stop. Info The adjustment screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of turns according to the fork type. Guideline Spring preload - Preload Adjuster Comfort...

  • Page 134: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 135: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 136: Adjusting The Rebound Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 work- shop will be pleased to help.) – Turn adjusting screw clockwise up to the last perceptible click.
  • Page 137 TUNING THE CHASSIS Info The spring preload defines the initial situation of the spring process on the shock absorber. The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.

  • Page 138: Steering Damper

    TUNING THE CHASSIS Info Turn clockwise to increase preload, turn counterclockwise to reduce spring preload. – Tighten screw Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) 100689-10 Steering damper 9.10 The steering damper suppresses shocks to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel.

  • Page 139: Adjusting The Steering Damper

    TUNING THE CHASSIS Adjusting the steering damper 9.11 Info The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load. In contrast to other damping elements, the steering damper is adjusted with the damping element open. –...

  • Page 140: Vehicle Level

    TUNING THE CHASSIS Vehicle level 9.12 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behav- ior. 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 141: Adjusting Front Vehicle Level

    TUNING THE CHASSIS Adjusting front vehicle level 9.13 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. – Loosen screws on the lower triple clamp.
  • Page 142 TUNING THE CHASSIS Info The standard adjustment is the setting that provides the best vehicle handling. When the fork is compressed, the suspension setting changes, causing the vehi- cle to become more stable but also more difficult to handle. – Tighten screw Guideline Screw, top triple clamp...

  • Page 143: Adjusting The Vehicle Level At The Rear

    TUNING THE CHASSIS Adjusting the vehicle level at the rear 9.14 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...

  • Page 144: Footrest Position

    TUNING THE CHASSIS – Tighten screw Guideline Screw, clamp, eccentric shaft of deflec- 18 Nm (13.3 lbf ft) 100698-10 Footrest position 9.15 The adjustable footrest system enables an individual setting of the footrest height and an individual adjustment of the controls. The lower footrest position enables a more comfortable knee angle, the upper footrest posi- tion a sporting sitting position and more forward-leaning freedom for use in racing.
  • Page 145 TUNING THE CHASSIS – Remove screws B00561-10 – Position the footrest bracket with spacers and screws. Guideline Standard Upper position Info The adjustable footrest bracket enables a more comfortable lower footrest posi- tion or a sporting upper footrest position. B00562-10 –...
  • Page 146 TUNING THE CHASSIS – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( p. 146) – Adjust the foot brake lever. ( p. 150) 100702-01...

  • Page 147: Adjusting Shift Lever Stub

    TUNING THE CHASSIS Adjusting shift lever stub 9.17 – 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 148: Adjusting The Foot Brake Lever Stub

    TUNING THE CHASSIS Adjusting the foot brake lever stub 9.18 – Remove the screw with the foot brake lever stub. – Position the foot brake lever stub with the screw in one of the holes according to the desired lever length. Guideline Standard Central hole...
  • Page 149 TUNING THE CHASSIS – Remove screws and take off the shift rod. – Loosen lock nuts – Adjust the shift rod. Guideline Shift rod adjustment range 114… 153 mm (4.49… 6.02 in) Info Make the same adjustments on both sides. At least 5 screw threads must be screwed into the seating.
  • Page 150 TUNING THE CHASSIS – Position the shift rod. Guideline Standard shift lever: upper drill hole, shift shaft: lower drill hole 0 0 A Medium shift force, medium shift shift lever: lower drill hole, distance shift shaft: lower drill hole Shift power high, short shift travel shift lever: lower drill hole, shift shaft: upper drill hole 0 0 B...
  • Page 151 TUNING THE CHASSIS – Adjust the shift lever by turning the shift rod. Info The position of the shift lever can be greatly varied, depending on the length of the shift rod and the drill holes selected. As seen from the footrest, there is either a high position of the shift lever or a low position of the shift lever –...

  • Page 152: Adjusting The Foot Brake Lever

    TUNING THE CHASSIS Adjusting the foot brake lever 9.20 – Use the tool to press in the anti-rotation lock , then turn the piston rod Info The range of adjustment is limited. – Remove the tool. The spring tension on the anti-rotation lock is released and the hex nut is locked. 100707-10 –...

  • Page 153: Handlebar Height/Position

    TUNING THE CHASSIS – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The piston rod should not move in the process.

  • Page 154: Adjusting The Handlebar Height/Position

    TUNING THE CHASSIS Handlebar position The handlebar stubs can be set in position , enabling ergonomic adjustment of the handlebar position. Handlebar position difference 6.5° Standard Position 600925-10 Adjusting the handlebar height/position 9.23 Info The handlebar stub position must be identical on the left and right of the vehicle. Adjusting the high position of the handlebar stubs: –...
  • Page 155 TUNING THE CHASSIS – Remove distance sleeve – All cables routed under the upper triple clamp must now be routed under the han- dlebar stub. – Push the handlebar stub carefully up to the upper triple clamp. Watch out for the handlebar position difference.
  • Page 156 TUNING THE CHASSIS Adjusting the low position of the handlebar stubs: – Loosen screw Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub. 100759-10 – Remove screw with distance sleeve – Carefully shift the handlebar stub by the length of the distance sleeve.
  • Page 157 TUNING THE CHASSIS – Tighten the screw. Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) – Repeat the adjustments on the other handlebar stub. – Move the handlebar to and fro over the entire steering range. » If the cables restrict the freedom of movement of the steering: –...
  • Page 158 TUNING THE CHASSIS – Position the distance sleeve. – Mount and tighten screw Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) – Tighten screw Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) 600986-10 – Repeat the adjustments on the other handlebar stub. –...

  • Page 159: Rear Frame Position

    TUNING THE CHASSIS – Position the distance sleeve. – Mount and tighten screw Guideline Remaining frame bolts 5 Nm (3.7 lbf ft) – Tighten screw Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) 600986-11 – Repeat the adjustments on the other handlebar stub. –...

  • Page 160: Adjusting The Rear Frame Position

    TUNING THE CHASSIS Adjusting the rear frame position 9.25 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Preliminary work –...
  • Page 161 TUNING THE CHASSIS – Mount the screw and washer on the left and right sides of the vehicle, but do not tighten. 100764-01 – Remove screw with washer on the left and right sides of the vehicle. – Push the rear up until the drill holes of the frame are level with the lower rear drill holes of the rear.
  • Page 162 TUNING THE CHASSIS Setting a lower seat position: – Remove screw with washer on the left and right sides of the vehicle. – Push the rear end down until the drill holes of the frame are level with the upper rear drill holes of the rear.
  • Page 163 TUNING THE CHASSIS – Tighten screw on the left and right sides of the vehicle. Guideline Screw, subframe 20 Nm Loctite ® 243™ (14.8 lbf ft) 100765-12 – When you screw in the rear left fixing screw, the plug-in cable binder is pushed out of the thread.
  • Page 164 TUNING THE CHASSIS Subsequent work – Fit the seat. ( p. 166)

  • Page 165: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the front of the motorcycle with lifting gear 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Preliminary work –...

  • Page 166: Raising The Rear Of The Motorcycle With Lifting Gear

    SERVICE WORK ON THE CHASSIS Raising the rear of the motorcycle with lifting gear 10.3 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the lifting gear at the rear. Adapter (61029055120) Rear wheel stand (61029055400) –...

  • Page 167: Bleeding Fork Legs

    SERVICE WORK ON THE CHASSIS Bleeding fork legs 10.5 Preliminary work – Lean the motorcycle on the side stand. Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Perform this action on both fork legs.

  • Page 168: Fitting The Seat

    SERVICE WORK ON THE CHASSIS Fitting the seat 10.7 – Position the recesses of the seat to the lugs on the frame, lower the rear end and simul- taneously push it forward. – Lock the seat by turning the ignition key in the seat lock. –...

  • Page 169: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS Removing the passenger seat 10.9 – Remove the seat. ( p. 165) – Activate the release lever – Take off the passenger seat toward the top. 100731-10 Mounting the passenger seat 10.10 Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 170: Checking For Chain Dirt

    SERVICE WORK ON THE CHASSIS Checking for chain dirt 10.11 – Check the chain for loose dirt. » If the chain is very dirty: – Clean the chain. ( p. 168) 400678-01 Cleaning the chain 10.12 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 171: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.

  • Page 172: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS – 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 173 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust chain tension by turning the adjustment screws on the left and right. Guideline Chain tension 15… 20 mm (0.59… 0.79 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjuster are in the same position in relation to the reference marks...

  • Page 174: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket and engine sprocket 10.15 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 175 SERVICE WORK ON THE CHASSIS – Shift into neutral. – Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 176 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear at the opening. » If the rivets of the chain are no longer visible at the lower edge of the opening of the chain sliding guard: – Change the chain sliding guard.

  • Page 177: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting basic position of clutch lever 10.16 – 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 178: Correcting Fluid Level Of Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS – Check the fluid level. The fluid level must be between the MIN and MAX markings. » If the coolant level does not meet specifications: – Correct the fluid level of the hydraulic clutch. ( p.

  • Page 179: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM RC8 workshop will be pleased to help.) – Check the thickness of the brake disc in several places to see if it is within the speci-...

  • Page 180: Checking The Rear Brake Disc

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM RC8 workshop will be pleased to help.) – Check the thickness of the brake disc in several places to see if it conforms to measure-...

  • Page 181: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 182 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 183: Checking The Front Brake Linings

    11.6 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM RC8 workshop will be pleased to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 184: Checking The Rear Brake Fluid Level

    (Your authorized KTM RC8 workshop will be pleased to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.)

  • Page 185: Adding Rear Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.)

  • Page 186: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 100717-10 Checking the rear brake linings 11.9 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM RC8 workshop will be pleased to help.)
  • Page 187 BRAKES Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly. –...

  • Page 188: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 Preliminary work – Raise the rear of the motorcycle with lifting gear. ( p. 164) – Raise the front of the motorcycle with lifting gear. ( p. 163) Main work – Remove the screws from both brake calipers.

  • Page 189: Installing The Front Wheel

    WHEELS, TIRES – Remove spacers B00582-10 Installing the front wheel 12.2 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.
  • Page 190 WHEELS, TIRES – Insert the wide spacer on the left-hand side (when looking in the direction of travel). Info The arrow indicates the direction of rotation of the front wheel. – Insert the narrow spacer on the right-hand side (when viewed in the direction of travel). B00583-10 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the...
  • Page 191 WHEELS, TIRES – Position the brake calipers and check that the brake linings are seated correctly. – Mount screws on both brake calipers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 192: Removing The Rear Wheel

    WHEELS, TIRES Removing the rear wheel 12.3 Preliminary work – Raise the rear of the motorcycle with lifting gear. ( p. 164) Main work – Remove nut – Remove chain adjuster – Remove the axle B00585-10 – Push the rear wheel as far forward as possible and then remove the chain from the rear sprocket.

  • Page 193: Installing The Rear Wheel

    WHEELS, TIRES Installing the rear wheel 12.4 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.
  • Page 194 WHEELS, TIRES – Push the brake caliper frame completely to the rear. – Position the rear wheel, and place the brake caliper frame between the rim and the brake disc. – Slide the brake caliper onto the brake disc. – Position the rear wheel on the mating surfaces in the swingarm.

  • Page 195: Checking Rear Hub Cush Drive

    WHEELS, TIRES – Place the chain adjuster on the tensioning screw. – Position the chain adjuster and place it on the tensioning screw. – Tighten nut Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut, rear wheel spindle M25x1.5...

  • Page 196: Checking The Tire Condition

    Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM RC8 workshop will be pleased to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
  • Page 197 WHEELS, TIRES Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles.

  • Page 198: Checking The Tire Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years.
  • Page 199 WHEELS, TIRES – Mount the dust cap. Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is defective.

  • Page 200: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 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 201 ELECTRICAL SYSTEM Main work – Disconnect negative (minus) cable of the battery. 100734-10 – Remove the cover of the positive terminal. – Disconnect the positive (plus) cable of the battery. 100735-10 – Remove screws – Removing the securing bracket – Pull the battery up and out of the battery rack.

  • Page 202: Installing The Battery

    ELECTRICAL SYSTEM Installing the battery 13.2 Main work – Position the battery in the battery rack. Info The terminals of the battery must face the rear of the vehicle. – Position the bracket 100737-10 – Mount and tighten screws Guideline Remaining chassis screws 10 Nm (7.4 lbf ft) –...

  • Page 203: Recharging The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
  • Page 204 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery.
  • Page 205 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid Charge the battery at no more than 10% of the capacity specified on the battery...

  • Page 206: Changing The Main Fuse

    ELECTRICAL SYSTEM Changing the main fuse 13.4 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is under the seat. Preliminary work –...
  • Page 207 ELECTRICAL SYSTEM Main work – Remove protection covers – Remove the faulty main fuse Info A reserve fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p. 258) Place the spare fuse in the starter relay so that it is available if needed. –...

  • Page 208: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM Changing the fuses of individual power consumers 13.5 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preliminary work –...
  • Page 209 ELECTRICAL SYSTEM – Check the fuses. Info A defective fuse can be identified by the burned-out fuse wire – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, immobilizer, alarm system (optional) 100741-10 Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 3 - 10 A - horn, brake light Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - fuel pump...

  • Page 210: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM – Close the fuse box cover. Follow-up work – Fit the seat. ( p. 166) Changing the low beam bulb 13.6 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 211 ELECTRICAL SYSTEM – Release the latch – Remove the lamp cover 100743-10 – Disconnect plug-in connector – Push off the retaining clamp on both sides, squeeze and fold to the side. – Remove headlight bulb 700295-01 – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7 / base PX26d) ( p.
  • Page 212 ELECTRICAL SYSTEM – Position the lug of the lamp cover in the notch. Engage the latch – Check that the lighting is functioning properly. 401161-10 – Position the rubber holder – Fold down the combination instrument. Position the lug in the rubber retainer. 100742-10...

  • Page 213: Changing The High Beam Bulb

    ELECTRICAL SYSTEM Changing the high beam bulb 13.7 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 214 ELECTRICAL SYSTEM – Disconnect plug-in connector – Push off the retaining clamp on both sides, squeeze and fold to the side. – Remove headlight bulb. – Position the new headlight bulb in the headlight housing. Low beam / high beam (H7 / base PX26d) ( p.
  • Page 215 ELECTRICAL SYSTEM – Position the lug of the lamp cover in the notch. Engage the latch. – Check that the lighting is functioning properly. 401161-11 – Position the cover. Info Check for correct positioning and freedom of movement of the brake lines. –...

  • Page 216: Checking The Headlight Setting

    ELECTRICAL SYSTEM Checking the headlight setting 13.8 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...

  • Page 217: Activating/Deactivating Ignition Key

    ELECTRICAL SYSTEM Main work – Turn the screw to adjust the headlight range. Guideline A motorcycle with rider, including the luggage and a passenger (where applicable) the light cut off must be aligned exactly on the lower mark (when checking headlight adjustment).
  • Page 218 ELECTRICAL SYSTEM – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position EFI warning lamp (MIL) lights up, switches off, and then starts to flash. The immobilizer indicator lamp lights up.
  • Page 219 ELECTRICAL SYSTEM Loss of both black ignition keys (no black ignition key available): This procedure is important to prevent misuse of the lost black ignition key. – Press the emergency OFF switch into the position 401114-11 – Insert the orange programming key in the ignition lock. –...
  • Page 220 ELECTRICAL SYSTEM programmed during the activation procedure are invalid, but can be reprogrammed in a further activation procedure. – Press the emergency OFF switch into the position – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the ON position EFI warning lamp (MIL) lights up, switches off, and then starts to flash.

  • Page 221: Cooling System

    COOLING SYSTEM Cooling system 14.1 The water pump with a 3D water pump wheel in the engine ensures forced circulation of the coolant. The heat exchanger enables faster warming of the engine oil at the start of a journey and better heat dissipation for the engine oil during the journey. The pressure in the cooling system resulting from heat is regulated by a valve in the radi- ator cap .

  • Page 222: Filling Cooling System Compensating Tank

    COOLING SYSTEM Condition The engine is cold. The radiator is completely full. – Rest the motorcycle on its side stand on a horizontal surface. – Check the coolant level in the compensating tank. The coolant level must be between MIN and MAX. »...
  • Page 223 After draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model type. This is the only way of ensuring that the cooling system is filled without air bubbles. (Your authorized KTM RC8 workshop will be pleased to help.)

  • Page 224: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 225: Adjusting The Play In The Throttle Cable

    – Move the handlebar to the straight-ahead position. – Throttle position sensor circuit A - check in zero position. Info It is imperative to use the KTM diagnostics tool for this. – Push back protective cover – Loosen lock nut –...

  • Page 226: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level must be checked at normal engine operating temperature. Preliminary work – Stand the motorcycle upright on a horizontal surface. Main work – Remove oil dipstick .

  • Page 227: Changing Engine Oil And Filter, Cleaning Oil Screen

    SERVICE WORK ON THE ENGINE Changing engine oil and filter, cleaning oil screen 16.2 – Drain the engine oil and clean the oil screens. p. 225) – Fill up with engine oil. p. 230) 500281-01 Draining engine oil, cleaning oil screens 16.3 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
  • Page 228 SERVICE WORK ON THE ENGINE – Remove screws – Take off the left exhaust cover 100771-10 – Stand the motorcycle on its side stand on a level surface. – Place a suitable container under the engine. – Remove oil drain plug with the magnet, O-rings and oil screen.
  • Page 229 SERVICE WORK ON THE ENGINE – Thoroughly clean magnet and oil screen of the oil drain plug. 100773-10 – Mount and tighten the oil drain plugs with the magnet, O-rings, and oil screen. Guideline Oil drain plug M20x1.5 20 Nm (14.8 lbf ft) –...

  • Page 230: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE – Position the left exhaust cover – Mount and tighten screws Guideline Screw, painted trim parts 3.5 Nm (2.58 lbf ft) 100771-10 Removing the oil filter 16.4 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –...
  • Page 231 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preliminary work – Place a suitable container under the engine. Main work –...

  • Page 232: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE Installing the oil filter 16.5 – Insert oil filter – Lubricate the O-ring of the oil filter cover. Mount oil filter cover – Mount and tighten the screws. Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 100776-10 Filling up with engine oil 16.6...
  • Page 233 SERVICE WORK ON THE ENGINE Engine oil (1st 3.00 l (3.17 qt.) External Engine oil quantity) temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 267) External Engine oil (SAE temperature: 5W/40) ( p. 267) < 0 °C (< 32 °F) –...

  • Page 234: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 235 SERVICE WORK ON THE ENGINE Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. – Replace oil dipstick Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

  • Page 236: Cleaning, Care

    CLEANING, CARE Cleaning motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 237: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. –...
  • Page 238 CLEANING, CARE – Clean the motorcycle. ( p. 234) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly clean the brake calipers and brake linings after they have cooled down while they are installed; use cold water and dry them well.

  • Page 239: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends raising the motorcycle. – Raise the rear of the motorcycle with lifting gear. ( p. 164) –...

  • Page 240: Putting Into Operation After Storage

    STORAGE – Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 241: Troubleshooting

    OFF switch defective – Check the emergency OFF switch. – Safety start system defective Read out the trouble code memory using the KTM diagnostics tool. – Immobilizer active Read the immobilizer blink code. – EFI control unit not activated Encode the EFI control unit.
  • Page 242 Clean plug connector and treat with contact dized spray. – Fault in fuel injection system Read out the trouble code memory using the KTM diagnostics tool. – Fuel pump control defective Read out the trouble code memory using the KTM diagnostics tool. –...
  • Page 243 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 224) – Engine oil too thin (viscosity) Change the engine oil and filter, clean the oil screen. p. 225) –...

  • Page 244: Immobilizer Blink Code

    IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short Error level condition All ignition keys inactive Blink code of immobilizer indica- tor lamp 13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short Error level condition ICU antenna malfunction Blink code of immobilizer indica-...
  • Page 245 IMMOBILIZER BLINK CODE Blink code of immobilizer indica- tor lamp 21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short Error level condition Immobilizer control unit not activated Blink code of immobilizer indica- tor lamp 31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short Error level condition Malfunction, encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica-...

  • Page 246: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 02 EFI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code EFI warning lamp (MIL) 06 EFI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high...
  • Page 247 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 12 EFI warning lamp (MIL) flashes 1x long, 2x short Error level condition Engine coolant temperature sensor - input signal too low Engine coolant temperature sensor - input signal too high Blink code EFI warning lamp (MIL) 13 EFI warning lamp (MIL) flashes 1x long, 3x short Error level condition...
  • Page 248 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 18 EFI warning lamp (MIL) flashes 1x long, 8x short Error level condition Lambda sensor cylinder 2, sensor 1 - circuit fault Blink code EFI warning lamp (MIL) 22 EFI warning lamp (MIL) flashes 2x long, 2x short Error level condition Gear position sensor - circuit fault Blink code EFI warning lamp (MIL)
  • Page 249 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 34 EFI warning lamp (MIL) flashes 3x long, 4x short Error level condition Injector cylinder 2 - circuit fault Blink code EFI warning lamp (MIL) 37 EFI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code EFI warning lamp (MIL)
  • Page 250 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 41 EFI warning lamp (MIL) flashes 4x long, 1x short Error level condition Fuel pump control - short circuit to ground or open circuit Fuel pump control - input signal too high Blink code EFI warning lamp (MIL) 45 EFI warning lamp (MIL) flashes 4x long, 5x short Error level condition...
  • Page 251 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 53 EFI warning lamp (MIL) flashes 5x long, 3x short Error level condition Fuel evaporation valve - short circuit to ground or open circuit Fuel evaporation valve - input signal too high Blink code EFI warning lamp (MIL) 54 EFI warning lamp (MIL) flashes 5x long, 4x short Error level condition...
  • Page 252 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 91 EFI warning lamp (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error...

  • Page 253: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 42 mm (1.65 in) Exhaust...

  • Page 254: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug Inside spark plug NGK LKAR9BI9 Outside spark plug...

  • Page 255: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 22.2 Coolant 2.60 l (2.75 qt.) Coolant ( p. 266) Coolant (mixed ready to use) ( p. 266)

  • Page 256: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 257 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, stator 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, valve cover 10 Nm (7.4 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) ® Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 258 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° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) –...

  • Page 259: 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 120 mm (4.72 in) Brake system Front Twin floating disc with radial mount, 4-piston calipers Rear...

  • Page 260: Lighting Equipment

    TECHNICAL DATA - CHASSIS Steering head angle 66.7° Wheelbase 1,425 mm (56.1 in) Seat height, unloaded Lower frame rear position 805 mm (31.69 in) Upper frame rear position 825 mm (32.48 in) Ground clearance, unloaded 110 mm (4.33 in) Weight without fuel approx. 186 kg (410 lb.) Maximum permissible front axle load 150 kg (331 lb.)

  • Page 261: Tires

    120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Dunlop Sportmax Sportsmart Dunlop Sportmax Sportsmart Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 24.3 Total fuel tank capacity, approx. 16.5 l (4.36 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 262: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 05.18.7K.07 Fork WP Suspension Up Side Down 4354 Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 20 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Spring preload - Preload Adjuster...

  • Page 263: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 17.18.7K.07 Shock absorber WP Suspension 4014 VP Compression damping, high-speed Comfort 3 turns Standard 2.5 turns Sport 1.5 turns Full payload 1.5 turns Compression damping, low-speed Comfort 20 clicks Standard 20 clicks Sport 20 clicks Full payload...
  • Page 264 TECHNICAL DATA - SHOCK ABSORBER Spring length 160 mm (6.3 in) Gas pressure 10 bar (145 psi) Static sag 11… 15 mm (0.43… 0.59 in) Riding sag 28… 35 mm (1.1… 1.38 in) Inbuilt length 290 mm (11.42 in) Shock absorber oil ( p.

  • Page 265: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ – Remaining frame bolts 5 Nm (3.7 lbf ft) ® Screw, brake fluid reservoir of rear brake 5 Nm (3.7 lbf ft) Loctite 243™...
  • Page 266 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, shift shaft deflector on shift 18 Nm (13.3 lbf ft) Loctite 243™ shaft – Fork end pinch bolts 15 Nm (11.1 lbf ft) ® Nut, forked bracket on foot brake lever 30 Nm (22.1 lbf ft) Loctite 243™...
  • Page 267 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, steering damper fixing bracket 10 Nm (7.4 lbf ft) Loctite 243™ on triple clamp – Screw, steering stem 20 Nm (14.8 lbf ft) ® Screw, subframe 20 Nm (14.8 lbf ft) Loctite 243™...

  • Page 268: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 269 SAE ( p. 272) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Fully synthetic engine oil Supplier ® Motorex –...
  • Page 270 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
  • Page 271 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 272: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 273 AUXILIARY SUBSTANCES Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ®...

  • Page 274: 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 specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 275: Index

    INDEX Braking ........120 INDEX Accessories .
  • Page 276 INDEX gear display menu, LastLap/RaceTrip/Gear ..56, 83, 87 gear display menu, ODO/Trip 1/Gear ... 47, 82, 86 Electric starter button ......33 indicator lamps .
  • Page 277 INDEX checking free travel ......150 handlebar height, adjusting ..... 152 handlebar position .
  • Page 278 INDEX removing ........228 Loading the vehicle ......111 Low beam bulb Oil screen changing .
  • Page 279 INDEX Rear sprocket Shifting ........117 checking .
  • Page 280 INDEX Tire air pressure checking ........196 Tire condition checking .
  • Page 281 *3211786en* 3211786en 12/2011 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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