KTM 1190 RC8 JP, 1190 RC8 FR, 1190 RC8, 1190 RC8 AUS-UK User Manual

5 (1)
KTM 1190 RC8 JP, 1190 RC8 FR, 1190 RC8, 1190 RC8 AUS-UK User Manual

OWNER'S MANUAL 2008

1190 RC8 EU

1190 RC8 AUS/UK

1190 RC8 FR

1190 RC8 JP

ART. NO. 3211250en

DEAR KTM CUSTOMER

1

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Please enter the serial numbers of your vehicle below.

Chassis number/type label ( S. 16)

Dealer's stamp

Engine number ( S. 17)

Key number ( S. 16)

The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small deviations arising from further development in design and construction.

All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER

2

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

CONTENTS

3

MEANS OF REPRESENTATION ...............................................

7

IMPORTANT NOTES...............................................................

8

VIEW OF VEHICLE................................................................

12

View of vehicle, front left side............................................

12

View of vehicle, rear right side ...........................................

14

LOCATION OF SERIAL NUMBERS .........................................

16

Chassis number/type label.................................................

16

Key number .....................................................................

16

Engine number.................................................................

17

Fork part number..............................................................

17

Shock absorber part number..............................................

18

Steering damper part number ............................................

18

OPERATING ELEMENTS.......................................................

19

Clutch lever .....................................................................

19

Hand brake lever ..............................................................

19

Light switch .....................................................................

20

Headlight flasher switch....................................................

20

Flasher switch..................................................................

21

Horn button .....................................................................

21

Ignition/steering lock ........................................................

22

Emergency OFF switch......................................................

22

Electric starter button .......................................................

23

Combination instrument - overview.....................................

24

Combination instrument - function buttons on handlebar .....

25

Combination instrument - activation and test ......................

26

display ............................................................................

27

info display......................................................................

28

Indicator lamps ................................................................

29

Notes/warnings on the combination instrument....................

30

ODO menu.......................................................................

33

FUELDISTANCE menu......................................................

34

FUELRANGE menu...........................................................

35

DISTANCE TO Next Service menu ......................................

36

LAPSTOGO menu .............................................................

37

TOPSPEED menu .............................................................

38

LAP/BESTLAP/LastLap menu.............................................

39

LAP/BESTLAP/TopSpeed menu..........................................

40

Total distance menu in Race mode RACEODO.....................

41

SET UP menu ..................................................................

42

CHANGE MODE menu ......................................................

43

SET CLOCK menu ............................................................

44

SETTINGS menu ..............................................................

45

SHIFT RPMS menu ..........................................................

46

LAP menu, LAP BLANK T button .......................................

47

SET NUM LAPS menu ......................................................

48

TRIP F RESET menu.........................................................

49

UNITS menu....................................................................

50

SET KM/MILES menu .......................................................

51

SET °C/°F menu ...............................................................

52

OPTIONS menu................................................................

53

TPMS menu.....................................................................

54

OPTION OUTERTEMP menu..............................................

55

Displaying lap times .........................................................

60

Displaying maximum speed ...............................................

61

Setting ROAD or RACE mode .............................................

62

Setting the clock with SET CLOCK .....................................

62

Adjusting shift speed RPM1/2 ...........................................

63

Setting the blank time of the LAP button LAP BLANK T .......

65

CONTENTS

4

Setting number of laps SET NUM LAPS..............................

66

Setting fuel reserve display TRIPF RESET...........................

67

Setting kilometers/miles SET KM/MILES.............................

68

Setting temperature unit SET °C/°F ....................................

69

Switching external temperature display on/off......................

69

Opening the filler cap .......................................................

71

Closing the filler cap.........................................................

72

Supporting strap...............................................................

72

Seat lock .........................................................................

73

Tool set ...........................................................................

73

Helmet lock .....................................................................

74

Passenger footrests...........................................................

74

Shift lever........................................................................

75

Foot brake pedal ..............................................................

76

Side stand .......................................................................

76

TIPS ON PUTTING INTO OPERATION ....................................

77

advice on first use ............................................................

77

Running the engine in.......................................................

78

Loading the vehicle ..........................................................

79

RIDING INSTRUCTIONS .......................................................

81

checks to be made before putting into operation..................

81

Starting ...........................................................................

82

starting up .......................................................................

83

Shifting, riding.................................................................

84

Braking ...........................................................................

87

Stopping, parking .............................................................

88

Refueling.........................................................................

89

GREASING AND SERVICE TABLE ..........................................

91

Important service tasks to be carried out by an authorized

 

KTM-RC8 workshop. .........................................................

91

Important service tasks to be carried out by an authorized

 

KTM-RC8 workshop. (as additional job) ..............................

94

MAINTENANCE WORK ON CHASSIS AND ENGINE.................

95

Jacking up motorcycle front...............................................

95

Taking front of motorcycle off work stand............................

95

Jacking up motorcycle rear ................................................

96

Taking rear of motorcycle off work stand .............................

96

Fork/shock absorber..........................................................

97

Adjusting compression damping of fork ..............................

97

Adjusting rebound damping of fork.....................................

98

Adjusting spring preload of fork .........................................

99

bleeding fork legs ...........................................................

100

Compression damping of the shock absorber .....................

101

Adjusting the low-speed compression damping of the

 

shock absorber ...............................................................

101

Adjusting high-speed compression damping of the shock

 

absorber ........................................................................

103

Adjusting rebound damping of the shock absorber .............

104

Adjusting spring preload of shock absorber x...................

104

Steering damper.............................................................

107

Adjusting the steering damper .........................................

107

Vehicle level ..................................................................

109

Adjusting vehicle level, front x.......................................

110

Adjusting vehicle level at rear ..........................................

111

Footrest position.............................................................

113

Adjusting footrest position...............................................

113

Adjusting shift lever stub.................................................

116

CONTENTS

5

Adjusting shift lever........................................................

116

Adjusting the footbrake pedal stub ...................................

120

Adjusting the footbrake pedal ..........................................

121

checking for chain dirt ....................................................

121

Cleaning the chain..........................................................

122

Checking the chain tension .............................................

123

Adjusting the chain tension .............................................

124

Checking rear sprocket / engine sprocket for wear ..............

126

Checking chain wear.......................................................

127

Checking chain sliding guard ...........................................

128

Checking front brake discs ..............................................

128

Checking rear brake disc .................................................

129

Adjusting the basic position of the handbrake lever............

129

Checking brake fluid level of front brake ...........................

130

Topping up brake fluid of front brake x...........................

130

Brake linings..................................................................

132

Checking the front brake linings.......................................

132

Checking rear brake fluid level.........................................

133

Topping up rear brake fluid x........................................

134

Checking the rear brake linings ........................................

135

Removing front wheel x................................................

136

Fitting front wheel x.....................................................

137

Removing rear wheel x..................................................

138

fitting the rear wheel x..................................................

140

Checking rear hub shock absorbers x..............................

143

Tire condition checking...................................................

143

Checking tire air pressure................................................

145

Removing the seat ..........................................................

146

Fitting the seat...............................................................

146

Removing passenger seat ................................................

147

Fitting the passenger seat ...............................................

147

Mounting helmet lock on vehicle......................................

148

Removing the battery x.................................................

148

Installing the battery x..................................................

150

Recharging the battery x...............................................

151

Changing the main fuse ..................................................

153

Changing fuses of individual power consumers ..................

155

Changing the low beam bulb............................................

157

Change the high beam bulb.............................................

160

Changing the parking light bulb .......................................

164

Checking headlight adjustment ........................................

167

Adjusting headlamp range ...............................................

167

Activating/deactivating ignition key ..................................

168

Cooling system ...............................................................

171

Checking the coolant level...............................................

172

Filling the cooling system compensating tank....................

173

Adjusting basic position of clutch lever.............................

175

Checking fluid level of hydraulic clutch ............................

175

Correcting fluid level of hydraulic clutch...........................

176

Adjusting gas Bowden cable x.......................................

177

Handlebar height............................................................

177

Adjusting handlebar height..............................................

178

Rear frame position ........................................................

179

Adjusting rear frame position ...........................................

180

Checking engine oil level.................................................

184

Changing engine oil and filter, cleaning oil screen x........

185

Draining engine oil, cleaning oil screens x......................

185

Removing oil filter x.....................................................

188

CONTENTS

6

Fitting oil filter x..........................................................

190

Filling up with engine oil x............................................

190

Topping up engine oil .....................................................

192

TROUBLESHOOTING..........................................................

194

IMMOBILIZER FLASH CODE ...............................................

197

ENGINE CONTROL FLASH CODE.........................................

198

CLEANING.........................................................................

202

Cleaning motorcycle .......................................................

202

CONSERVATION FOR WINTER OPERATION .........................

204

Conservation for winter operation .....................................

204

STORAGE ..........................................................................

205

Storage..........................................................................

205

Putting into operation after storage ..................................

206

TECHNICAL DATA - ENGINE...............................................

207

Capacity - engine oil .......................................................

208

Capacity - coolant...........................................................

208

TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........

209

TECHNICAL DATA - CHASSIS .............................................

212

Lighting equipment ........................................................

213

Capacity - fuel................................................................

214

TECHNICAL DATA - FORK...................................................

215

TECHNICAL DATA - SHOCK ABSORBER ..............................

216

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........

218

SUBSTANCES....................................................................

221

AUXILIARY SUBSTANCES...................................................

224

STANDARDS......................................................................

226

INDEX ...............................................................................

227

MEANS OF REPRESENTATION

7

Symbols used

The following explains the meaning of specific symbols.

Identifies an expected reaction (e.g. of an operation or a function).

Identifies an unexpected reaction (e.g. of an operation or a function).

All jobs marked with this symbol require specialist knowledge and technical understanding. In the interests of your own safety, have these jobs done in an authorized KTM-RC8 workshop! There, your motorcycle will be handled optimally by specially trained experts with the necessary special tools.

Identifies a page reference (more information is provided on the specified page).

Formats used

The type formats used are explained here.

Specific name

Identifies a name.

Name®

Identifies a protected name.

Brand™

Identifies a trademark.

 

 

IMPORTANT NOTES

8

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.

Maintenance

A prerequisite for fault-free operation and avoiding premature wear is compliance with the maintenance, care and adjustments to the engine and chassis described in the service manual. Poor suspension settings can cause damage and breakage to chassis components. Using the motorcycle in extreme conditions such as racing can lead to above-average wear to components such as the power train or brakes. It may therefore be necessary to service or replace worn parts before the wear limit shown in the greasing and service table is reached.

Pay special attention to the prescribed running-in times, inspection and maintenance intervals. Proper compliance will contribute considerably to a longer service life of your motorcycle.

Warranty

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

Materials

The fuels and lubricants named in the owner's manual must be used according to specifications.

Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM-RC8 workshop. KTM accepts no liability for other products and any resulting damage.

IMPORTANT NOTES

9

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts.

Following servicing, the vehicle must be checked for roadworthiness.

Transport

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

Do not place the vehicle where there are flammable or explosive substances.

Switch off the engine and remove the ignition key.

Secure the motorcycle against falling over or running away using straps or other suitable devices.

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 conflicts. To ensure the future of motorcycle sport, make sure you use the motorcycle legally, demonstrate a consciousness for the environment, and respect the rights of others.

IMPORTANT NOTES

10

notes/warnings

Be sure to pay attention to the notes and warnings given here.

Info

Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If these are removed, you or other persons may not recognize potential danger and therefore be liable to injury.

Grades of risks

Danger

Danger of leading to immediate, certain, serious, permanent injuries or death.

Warning

Danger of probable, serious, permanent injuries or death.

Note

Danger of considerable engine or material damage.

Warning

Danger of environmental damage.

Operating instructions

Be sure to read these operating instructions carefully and completely before taking your first ride. They contain much information and tips that will help you to operate and handle your motorcycle. Only in this way will you find out how to adjust the motorcycle best for your own use and how to protect yourself from injury. These operating instructions also contain important information about servicing the motorcycle.

The service manual is an important component of the motorcycle and should be passed on to the new owner if the bike is sold.

11

 

VIEW OF VEHICLE

12

 

 

 

 

 

3View.1 of vehicle, front left side

 

 

700243-10

 

VIEW OF VEHICLE

13

 

 

 

 

 

1

Clutch lever

 

 

 

 

 

 

 

2

Light switch, headlight flasher switch, indicator switch, horn button

 

 

 

 

 

 

 

3

Filler cap

 

 

 

 

 

 

 

4

Seat

 

 

 

 

 

 

 

5

Seat lock

 

 

 

 

 

 

 

6

Oil dipstick

 

 

 

 

 

 

 

7

Side stand

 

 

 

 

 

 

 

8

Shift lever

 

 

 

 

 

 

 

9

Passenger footrests

 

 

 

 

 

 

 

 

VIEW OF VEHICLE

14

 

 

 

 

 

View3.2 of vehicle, rear right side

 

 

 

 

 

 

700242-10

VIEW OF VEHICLE

15

1Passenger seat

2Supporting strap

3Rear mirror

4Combination instrument

5Emergency OFF switch, electric starter button

6Hand brake lever

7Chassis number, type label

8Rear brake caliper

9Foot brake pedal

10Engine number

11Brake calipers, front

LOCATION OF SERIAL NUMBERS

16

4Chassis.1 number/type label

The chassis number is stamped on the frame behind the steering head on the right.

The type label is on the frame above the chassis number.

700231-01

Key4.2 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.

700222-01

LOCATION OF SERIAL NUMBERS

17

Engine4.3 number

The engine number is stamped on the right side of the engine.

700223-01

Fork4.4 part number

The fork part number is stamped on the inner side of the fork stub.

700224-01

LOCATION OF SERIAL NUMBERS

18

Shock4.5 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.

700225-01

Steering4.6 damper part number

The steering damper part number is stamped on the top of the steering damper.

700226-01

OPERATING ELEMENTS

19

5Clutch.1 lever

The clutch lever is fitted on the left side of the handlebar.

The clutch is hydraulic and self-adjusting.

700227-01

Hand5.2 brake lever

The handbrake lever is fitted on the right side of the handlebar.

The hand brake lever operates the front brake.

700228-01

OPERATING ELEMENTS

20

Light5.3 switch

The light switch is fitted on the left side of the handlebar.

Possible states

Low beam on – Light switch is turned downwards. In this position, the low

beam and tail light are switched on.

High beam on – Light switch is turned upwards. In this position, the low beam, the high beam and the tail light are switched on.

700230-13

Headlight5.4 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 operated in this position.

700232-01

OPERATING ELEMENTS

21

Flasher5.5 switch

The flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off

Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

700230-12

Horn5.6 button

The horn button is fitted on the left side of the handlebar.

Possible states

Horn button in neutral position

Horn button pressed – The horn is operated in this position.

700230-11

OPERATING ELEMENTS

22

Ignition/steering5.7 lock

The ignition/steering lock is located in front of the upper triple clamp.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The black ignition key can be removed.

Ignition on – In this position, the ignition circuit is closed, and the engine can be started.

Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The black ignition key can be removed.

700234-01

Emergency5.8 OFF switch

The emergency OFF switch is fitted on the right side of the handlebar.

Possible states

Emergency OFF switch on – This position is necessary for operation, the ignition circuit is closed.

Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started.

700229-11

OPERATING ELEMENTS

23

Electric5.9 starter button

The electric starter button is fitted on the right side of the handlebar.

Possible states

Electric starter button in neutral position

Electric starter button pressed – In this position, the electric starter is operated.

700229-12

OPERATING ELEMENTS

24

Combination5.10 instrument - overview

1display ( S. 27)

2Function buttons

3Indicator lamps ( S. 29)

4info display ( S. 28)

400430-10

 

OPERATING ELEMENTS

25

 

 

 

 

 

 

 

Combination5.11

instrument - function buttons on handlebar

 

 

 

 

 

The Mode button is fitted on the handlebar, front left.

 

 

 

 

 

 

 

 

 

 

The Lap button is fitted on the handlebar, rear left.

 

 

600642-10

 

OPERATING ELEMENTS

26

 

 

 

 

 

 

 

Combination5.12

instrument - activation and test

 

 

 

 

 

Activation

 

 

 

 

 

 

 

 

 

 

The combination instrument is activated when the ignition is switched on.

 

 

 

 

 

Test

 

 

 

 

 

The segments of the tachometer light up in and switch off in sequence.

 

 

 

 

 

The speed display counts from 0 to 300 and back.

 

 

 

 

 

The remaining display segments outside the info display light up briefly.

 

 

 

 

 

The KTM logo appears in the info display.

 

 

 

 

 

In ROAD mode, the info display switches to ODO, TripDist, TripTime, AvgSpeed mode.

 

 

 

 

 

In RACE mode, the info display switches to LAPSTOGO, LastLap, ±Last, ±Best mode.

 

 

400429-10

 

OPERATING ELEMENTS

27

 

 

 

 

 

 

 

 

 

display5.13

 

 

 

 

 

 

 

 

 

The tachometer displays the engine speed in revolutions per minute (RPM).

 

 

 

 

 

The red marking marks the over-rev (excessive speed) range of the engine.

 

 

 

The speed is displayed in kilometers per hour km/h or in miles per hour Mph.

 

 

 

The time appears in segment .

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Info

 

 

 

 

 

 

 

 

 

 

 

 

After reconnecting the battery or changing the fuse, the time must be reset.

 

 

 

 

 

 

 

 

The coolant temperature is shown in degrees Celsius or Fahrenheit in segment .

 

 

 

The info display shows additional information.

400430-12

 

OPERATING ELEMENTS

28

 

 

 

 

 

 

 

 

info5.14

display

 

 

 

 

 

 

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 courses. It allows riders to time laps themselves.

 

 

 

 

If the general warning lamp

lights up, the corresponding message is shown periodically

 

 

 

 

in the info display.

 

 

 

 

 

 

 

 

 

 

 

 

 

Information repeat

45 s

 

 

 

 

 

 

 

 

The information shown in the info display can be controlled with the function buttons.

400430-13

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