Page 1
1190 RC8 2009
SPARE PARTS MANUAL: ENGINE
ART.NO.: 3CM089850IEN
ENGLISH
Page 2
Page 3
SPECIAL TOOLS
BALANCER SHAFT
CYLINDER
1190 RC8 2009
ENGINE CASE
CLUTCH COVER
TRANSMISSION I - MAIN SHAFT
3x
CRANKSHAFT, PISTON
7x
TRANSMISSION II - COUNTERSHAFT
4x
SECONDARY AIR SYSTEM SAS
8x
SHIFTING MECHANISM
5x
CLUTCH
9x
WATER PUMP
6x
10x
1
11x
12x
13x
15x
Page 4
COOLING SYSTEM
VALVE DRIVE
TIMING DRIVE
1190 RC8 2009
CYLINDER HEAD REAR
CYLINDER HEAD FRONT
THROTTLE BODY
16x
20x
LUBRICATING SYSTEM
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical
specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local
conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing
certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,
descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
© by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only.
17x
21x
IGNITION SYSTEM
18x
23x
19x
ELECTRIC STARTER
24x
2
25x
Page 5
SPECIAL TOOLS
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 61229001000 UNIVERSAL MOUNTING RACK 1
2 61229002000 ENGINE BRACKET 1
3 61229003000 CLUTCH HOLDER 1
4 61229005000 MOUNT. SLEEVE SHAFT SEAL RING 1
5 61229044000 PRESSING TOOL D53 MAIN BEARING 1
6 61229045000 BEARING RING F. PRESSING TOOL 1
7 61229010000 PULLER CPL. F. IGNITION COVER 1
8 61229020000 RING F. COMB. SHAFT BEARING 1
9 61229013000 ARBOR PRESS SS-RING DRIVE 1
10 61229015000 ENGINE BLOCKING SCREW 1
11 61229016000 PRES.SOCKET COUNTERSHAFT DRIVE 1
12 61229017000 PULLER F. COUNTERSHAFT DRIVE 1
13 61229018000 COMBINATION PRESSURE PAD 1
14 61229025000 EXTENSION TORQUE WRENCH 1
15 61229021000 UNLOCKING TOOL 1
16 61229008000 PRES. PEACE F. ROTOR EXTRACTOR 1
17 58429009000 MAGNETO EXTRACTOR 1
18 61229050000 FRAME SUPPORT 1
19 61229051000 CENTERING PIN 1
3
086122910 / C086122910
* NEW PART
X AS REQUIRED
Page 6
BALANCER SHAFT
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 61230057060 STOP DISK 15,2X25X1 2
2 61230058050 BEARING BOLT 15X39 08 1
3 0405151917 NEEDLE BEARING K 15X19X17 1
4 61230058000 BALANCER SHAFT L/S 08 1
4
086123030 / C086123030
* NEW PART
X AS REQUIRED
Page 7
CYLINDER
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 61230035000 CYLINDER BASE GASGET 08 2
2 61230005000 CYLINDER 08 2
3 0474050100 GROOVED PIN DIN1474 5X10 4
5
086123040 / C086123040
* NEW PART
X AS REQUIRED
Page 8
ENGINE CASE
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1* 6123000004424 ENGINE CASE CPL. WITH BEARINGS 1
2 0019050103 INT. TORX FLAT HEAD M 5X10 8.8 7
3 61230084000 BRACKET FOR BEARING INSERT 08 2
5 0025080306 HH COLLAR SCREW M8X30 TX40 3
6 61230066100 ENGINE BRACKET R/S 1
7 61230039100 MOLDED RING CASE CENTER 1
9 0025050166 HH COLLAR SCREW M5X16 TX30 2
10 75038041200 OILFILTER CAP 1
11 0770039026 O-RING 39,34X2,62 NBR 70 SH 1
12 0025060256 HH COLLAR SCREW M6X25 TX30 2
13 69030060044 PINION COVER CPL. 1
14 61230047044 CHAIN FAIL. PROTECTION CPL. 1
15 0412153511 CYL.ROLLER BEAR. NJ202 ECP C3 1
16 60030010000 SWING BEARING OUTSIDE LC8 03 2
17 60030023000 DOWEL 20,1X24X12 03 1
18 49030090000 DOWEL 9,8 X 7 X 10 3
19 61230044000 STUD M6X110 08 4
20 0025060806 HH COLLAR SCREW M6X80 TX30 16
21 61230043000 CASE SCREW M8X125 AS 08 5
22 0025060906 HH COLLAR SCREW M6X90 TX30 2
23 0025060506 HH COLLAR SCREW M6X50 TX30 1
24 60038029200 REDUCING JET "30" M6X0,75 1
25 0770090015 O-RING 9X1,5 NBR 1
26 77336056095 SCREW PLUG 1
27 0906200100 PLUG DIN0913-M10X1X8 2
28 0018050103 INT. TORX OVAL HEAD M 5X10 8.8 2
29 57031523140 MAIN JET 140 1
30 60005026000 SLS-VALVE 03 1
31 45038017000 SEAL RING 8X14X1 AI 1
32 0025080166 HH COLLAR SCREW M8X16 TX40 1
99* 61230099100 GASKET KIT ENGINE CPL. 1
6
086123010 / C096123010
* NEW PART
X AS REQUIRED
Page 9
CLUTCH COVER
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1* 6123002600041 OUTER CLUTCH COVER 09 1
2 61230027000 MOLDED RING OUTER CLUTCH COVER 1
3* 6123000104441 CLUTCH CASE WITH BEARINGS 1
4 61230025000 CLUTCH COVER GASGET 08 1
5 49030090000 DOWEL 9,8 X 7 X 10 2
10 0025060956 HH COLLAR SCREW M6X95 TX30 1
11 0025060306 HH COLLAR SCREW M6X30 TX30 9
12 0025060906 HH COLLAR SCREW M6X90 TX30 2
13 0025060456 HH COLLAR SCREW M6X45 TX30 5
14 0025060356 HH COLLAR SCREW M6X35 TX30 1
7
096123020 / C096123020
* NEW PART
X AS REQUIRED
Page 10
,
CRANKSHAFT
PISTON
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 61230015000 CONNECTING-ROD SCREW MJ10X1 08 4
2 0402040980 NEEDLE ROL.DIN5402 NRB 4X9,8 4
3* 61230013100 CONNECTING ROD CPL. 122MM 2
4 612300150101 SPLIT BEAR. BUSH RED 08 x
4 612300150102 SPLIT BEAR. BUSH BLUE 08 x
4 612300150103 SPLIT BEAR. BUSH YELLOW 08 x
5 0888040050 WOODRUFF KEY DIN6888 4X5X13 3
6 612300820001 SPLIT BEAR. BUSH RED 08 x
6 612300820002 SPLIT BEAR. BUSH BLUE 08 x
6 612300820003 SPLIT BEAR. BUSH YELLOW 08 x
7* 61230018300 CRANKSHAFT CPL. 1
8 60030026010 BUSHING BOWL 28X32X13 03 2
9 60032009050 HH-NUT M33X1,5 L/S WS46 03 1
10 60032009040 WASHER 33,2X46X2 03 1
11* 61230007400 I PISTON D=103 CPL. x
11* 61230007400 II PISTON D=103 CPL. x
12 61230033000 PISTON PIN D=20 08 2
13 77630074000 CIRCLIP 4
14 61230055000 PRIMARY GEAR 1
15 61230056000 DRIVE WHEEL BALANCER SHAFT 08 1
16 61230030000 L-RING 2
17 61230031000 PISTON RING MN 2
18 61230032000 PISTON RING GFSOE 2
8
086123060 / C096123060
* NEW PART
X AS REQUIRED
Page 11
SECONDARY AIR SYSTEM SAS
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1* 61205032000 SLS-FLANGE 1
2 61005026000 CONTROL VALVE SAS 05 1
3 69005035021 SAS HOSE-CYLINDER FRONT 1
4 69005035022 SAS HOSE-CYLINDER REAR 1
5 69005035023 SAS HOSE-AIR FILTER BOX 1
6 61205022000 SAS-FLANGE 1
7 60005026000 SLS-VALVE 03 2
8 00050226706 VARIABLE ONE-EAR CLAMP 22,6MM 3
9 00050210706 VARIABLE ONE-EAR CLAMP 21,0MM 2
10* 00049200121 CLAMP STD DN20 1
11 69005028100 SAS-SUPPORT RC8 08 1
12 69008021080 RANGE CHANGE METAL NUT M5 2
13 0025050126 HH COLLAR SCREW M5X12 TX30 2
14 0025060126 HH COLLAR SCREW M6X12 TX30 4
9
086123130 / C096123130
* NEW PART
X AS REQUIRED
Page 12
CLUTCH
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0984060162 AH SCREW DIN7984-M 6X16 6
2 61232006000 SPRING RETAINER STEPPED 6
3 61232005000 CLUTCH SPRING D2,7/35MM PINK 6
4 61232003000 PRESSURE CAP 1
5 0625060032 BALL BEARING 6003 JR2 C4 1
6 61232111000 LINING DISK OUTSIDE 3MM 1
7 61232010000 STEEL DISK 2MM 9
8 61232011000 LINING DISK 3MM 8
9 61232012000 LINING DISK INSIDE 3,8MM 1
10 61232034000 BELLEVILLE SPRING 1
11 61232035000 BEARING RING 1
12 0936220155 HEXAGON NUT DIN0936-M22X1,5 R. 1
13 0125220393 PULLEY 22X39X3MM 1
14 60032080000 CLUTCH BOOSTER UNIT CPL. 03 1
15 61232002000 CLUTCH TAPPET CPL. 1
16 60032021000 SECTION WASHER 03 1
17 61232001044 CLUTCH CAGE CPL. 08 1
18 60038001132 OIL PUMP GEAR WHEEL 32-T 07 1
19 0618303526 NEEDLE BUSH HK 30X35X26 1
20 60032020000 STOP DISK 30,2/50/2 1
21 61232054000 PUSH ROD CPL. 2-PARTS 08 1
23 0603100141 COPPER GASKET DIN7603-10X14X1 2
24 50332062000 HOLLOW SCREW CPL. M 10X1 '98 1
25 61232069000 PUSH ROD GUIDE 1
26 61232068100 DISTANCE PLATE 7MM 1
27 0025060506 HH COLLAR SCREW M6X50 TX30 2
28 60032061244 CYLINDER CPL. LC8 08 1
29 0025060256 HH COLLAR SCREW M6X25 TX30 1
30 60032061050 DISTANCE CLUTCH CONTR. CPL. 1
31 60032065000 O-RING GASKET 03 1
32 0760091862 SHAFT SEAL RING 9X18X06 B-NBR 1
33 61232061051 SLEEVE CLUTCH CONTR. 2
10
086123210 / C096123210
* NEW PART
X AS REQUIRED
Page 13
TRANSMISSION I - MAIN SHAFT
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0625062062 BALL BEARING 6206 C3 J1 NSK 1
2 61233001000 MAIN SHAFT 14T 1
3 0618091312 NEEDLE BUSH HK0912 9/13/12 03 1
4 0405263113 NEEDLE BEAR. K 26-31-13 1
5* 61233005100 IDLER GEAR 5.G 1
6 61233042000 STOP DISK 27,9/35,75/1,5 1
7 0417280150 LOCK RING DIN5417-WS28 1
8* 61233003100 SLIDING GEAR 3./4.G 1
9 61233041000 STOP DISK 22,2/30,2/1,5 1
10 0405222613 NEEDLE BEAR. K 22X26X13 TN 1
11* 61233006100 IDLER GEAR 6.G 1
12 61233002000 SOLID GEAR 2.G 1
13 0625062040 BALL BEARING 6204 DU J1 C3 1
14 60033040015 STOP DISK 20,2X28X1,5 x
14 60033040016 STOP DISK 20,2/28/1,6 x
14 60033040017 STOP DISK 20,2/28/1,7 x
14 60033040018 STOP DISK 20,2/28/1,8 x
14 60033040019 STOP DISK 20,2/28/1,9 x
14 60033040020 STOP DISK 20,2/28/2,0 x
14 60033040021 STOP DISK 20,2/28/2,1 x
14 60033040022 STOP DISK 20,2/28/2,2 x
11
086123330 / C096123330
* NEW PART
X AS REQUIRED
Page 14
TRANSMISSION II - COUNTERSHAFT
FIG PART NUMBER DESCRIPTION QTY
1 0471200120 CIRCLIP DIN471 20X1,2 1
2 60033040015 STOP DISK 20,2X28X1,5 1
3 0625062043 BALL BEARING 6204 J1 C3 1
4* 61233011100 IDLER GEAR 1.G 1
5 0405242813 NEEDLE BEAR. K 24X28X13 TN 1
6 60033044000 STOP DISK 24,3/35,75/1 1
7* 61233015100 SLIDING GEAR 5.G 1
8 0417290151 LOCK RING WS30 2
9 61233045000 STOP DISK 27/36/1,5 2
10* 61233014100 IDLER GEAR 4.G 1
11 0405263113 NEEDLE BEAR. K 26-31-13 3
12* 61233013100 IDLER GEAR 3.G 1
13* 61233016100 SLIDING GEAR 6.G 1
14 0471300151 CIRCLIP DIN0471-30X1,5 NIRO 1
15 61233046000 STOP DISK 29,9/39/1,5 1
16* 61233012100 IDLER GEAR 2.G 1
17 61233010000 COUNTER SHAFT 08 1
18 50330082000 CYL.ROLLER BEAR.NJ206 ET2XCS46 1
19 0760304772 SH.SEAL RING 30X47X7 BSL VITON 1
20 60033029016 CHAIN SPROCKET 16-T 03 x
20 60033029017 CHAIN SPROCKET 17-T 03 x
21 60033129017 CHAIN SPROCKET 17-T DAMPED 03 x
22 60033034000 SECURING PLATE TOOTHED 03 1
23 60033035000 HEXAGON NUT M20X1,5 03 1
24 60033043000 STOP DISK 20,2 X 34 X 1 1
1190 RC8 2009
12
086123360 / C096123360
* NEW PART
X AS REQUIRED
Page 15
SHIFTING MECHANISM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 54632095000 NEEDLE BEAR.HK 1412 14X20X12 2
2* 61234005144 SHIFT SHAFT CPL. 1
3* 0125060003 WASHER DIN0125-A 6,4 1
4 56534013100 TENSIONING SPRING 0,8MM 1
6 0760142460 SHAFT SEAL RING 14X24X6 B 1
7* 61234014000 RETURNSPRING 2MM 1
8 54634020000 SPRING GUIDE 1
9 54634050000 STOP DISK 14X30X1 1
10 58038023200 PRESSURE SPRING 0,9MM 4
11 59034020000 SHIFT RAIL 11,8X105MM 2
12 50334018100 SHIFTING ROLLER 6X8X5,2 3
13 61234002000 SHIFTING FORK 08 1
14 61234001000 SHIFTING FORK 08 1
15 0024060206 HH COLLAR SCREW M6X20 TX30 1
16 75034024044 LOCKING LEVER CPL. 07 1
17 75034052000 SLEEVE FOR LOCKING LEVER 07 1
18* 61234023000 SPRING - LOCKING LEVER 1
19 0012060303 AH SCREW DIN6912 M6X30 8.8 1
20* 61234015144 SHIFT DRUM LOCATING CPL. 1
21 0625618052 BALL BEARING 6805 C3 JR 1
22 61234003000 SHIFTING FORK 08 1
23 0625068080 GROOVED BALL BEARING 6808 JRC3 1
24* 61234012100 SHIFT ROLLER CPL. 09 1
25 60034014000 CONTACT SPRING 03 2
26 60034037000 CONTACT BOLT 03 2
27 0770275025 O-RING 27,5X2,5 NBR 1
28 0912050123 AH SCREW DIN0912-M 5X12 2
29 60011023100 GEAR-POSITION SENSOR 06 1
30* 69034040100 COLLAR BUSHING 1
31 0625006087 GROOVED BALL BEAR. 608 2RS C3 3
32* 6903403114401S SHIFTING LEVER CPL. 09 1
34 61034035000 RUBBER FOR SHIFT LEVER 05 1
35* 69034032100 GEAR LEVER 1
36* 0912060453 AH SCREW DIN0912-M 6X45 1
37 0025060166S HH COLLAR SCREW M6X16 ISA 30 1
38 69034036044 SHIFT ROD CPL. 1
13
096123410 / C096123410
* NEW PART
X AS REQUIRED
Page 16
SHIFTING MECHANISM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
39 69034041000 SPECIAL WASHER 6,4X21,4X2,6 1
40 0025060256 HH COLLAR SCREW M6X25 TX30 2
41 6900303801001 SPECIAL WASHER D=26X3 ALU ELO. 1
42 0025080306S HH COLLAR SCREW M8X30 TX40 1
43 59009062019 SPECIAL SCREW M6X19 WS=8 10.9 1
44 50233041000 PAIR OF WASHERS M 6 NORDLOCK 1
45 50232050001 STEEL WASHER 6,4X17X3 1
46 6903403000001S RESERVE GEAR CHANGE KIT 08 1
47 56509064100 SELF LOCKING NUT M6 10.9 1
14
096123410 / C096123410
* NEW PART
X AS REQUIRED
Page 17
WATER PUMP
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0025060106 HH COLLAR SCREW M6X10 TX30 1
2* 6123505200041 MOLDED RING WATER PUMP COV. 09 1
3 61235061000 MOLDED RING WATER PUMP COV. 08 1
4 0024060136 HH COLLAR SCREW M6X13 TX30 1
5 61235055000 WATER PUMP ROTOR 08 1
6 60035055150 FORM WASHER 16X1 NIRO 03 1
7 61235065044 WEAR BUSHING WITH SEAL RING 1
8 0025060456 HH COLLAR SCREW M6X45 TX30 5
9 0025060256 HH COLLAR SCREW M6X25 TX30 1
10 0770050012 O-RING 5,0X1,2 NBR 70 1
11 59030023000 DOWEL 6X8X11,5 2
12 0770090015 O-RING 9X1,5 NBR 1
13 0760153045 SHAFT SEAL RING 15/30/4,5 BAUD 2
14 04720300121 CIRCLIP DIN0472-30X1,2 NIRO 1
15 0412153511 CYL.ROLLER BEAR. NJ202 ECP C3 1
15
086123510 / C096123510
* NEW PART
X AS REQUIRED
Page 18
COOLING SYSTEM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 69035010000 COOLER "VW1585" CPL. 08 1
2 62535009000 RADIATOR CAP 1,4 BAR 1
3 0025060126 HH COLLAR SCREW M6X12 TX30 2
4 60035048000 ALU-GASKET 6X10X1.5 2
5 60035045000 THERMOSWITCH LC8 102DG '03 1
6 0770017015 O-RING 17X1,5 NB75 1
7 60035001000 SPECIAL SCREW M6X21 WS=8 2
8 41001052000 RUBBER SLEEVE D=12MM 3
9 69035091000 RADIATOR HOSE CPL. CYL.-FRONT 1
10 69035092000 RADIATOR HOSE CPL. CYL.-REAR 1
11 69035023000 PREFORMED HOSE COOLER/WAPU 08 1
12 54305058000 HOSE CLAMP 30-45 SGT 2
13 76235028000 HOSE CLAMP GEMI 20-32 MM 4
14 00050331706 VARIABLE ONE-EAR CLAMP 33,1MM 4
15 69035024000 PREFORMED HOSE COOLER INLET 08 2
16 69035028000 WATER PIPE CYL. REAR 08 1
17 69035027000 WATER PIPE CYL. FRONT 08 1
18 69035026000 PREFORMED HOSE CYL. REAR 08 1
19 69035025000 PREFORMED HOSE CYL. FRONT 08 1
20 69035065000 EXPANSION TANK CPL. 1
21 60035067001 HOSE 6X10 EPDM 03 x
22 58007117000 YDNAC-CLAMP 10107 10MM 3
24 60035066000 PLUG F. EXPANSION TANK 1
25 0024060136 HH COLLAR SCREW M6X13 TX30 2
30 69035030000 HOSE CLAMP 19/25 CPL. 08 1
31* 0024060206 HH COLLAR SCREW M6X20 TX30 1
32 61235017000 THERMOSTAT 70 DEGREE 2
33 0024060156 HH COLLAR SCREW M6X15 TX30 1
34 62635044050 FAN CLACK RUBBER 08 1
35 69035044000 FAN COWL WITH FAN 08 1
36 31008060000 RUBBER SLEEVE D=8MM OPEN 2
38 69008021060 SPECIAL SCREW M5X17 1
16
086123530 / C096123530
* NEW PART
X AS REQUIRED
Page 19
VALVE DRIVE
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 61236056000 VALVE LEVER SHAFT 08 4
2 61236060000 VALVE LEVER 08 8
3 60036035200 SHIM D=10/2,00 03 x
3 60036035205 SHIM D=10/2,05 03 x
3 60036035210 SHIM D=10/2,10 03 x
3 60036035215 SHIM D=10/2,15 03 x
3 60036035220 SHIM D=10/2,20 03 x
3 60036035225 SHIM D=10/2,25 03 x
3 60036035230 SHIM D=10/2,30 03 x
3 60036035235 SHIM D=10/2,35 03 x
3 60036035240 SHIM D=10/2,40 03 x
3 60036035245 SHIM D=10/2,45 03 x
3 60036035250 SHIM D=10/2,50 03 x
3 60036035255 SHIM D=10/2,55 03 x
3 60036035260 SHIM D=10/2,60 03 x
3 60036035265 SHIM D=10/2,65 03 x
3 60036035270 SHIM D=10/2,70 03 x
3 60036035275 SHIM D=10/2,75 03 x
3 60036035280 SHIM D=10/2,80 03 x
3 60036035285 SHIM D=10/2,85 03 x
3 60036035290 SHIM D=10/2,90 03 x
3 60036035295 SHIM D=10/2,95 03 x
3 60036035300 SHIM D=10/3,00 03 x
3 60036035305 SHIM D=10/3,05 03 x
3 60036035310 SHIM D=10/3,10 03 x
3 60036035315 SHIM D=10/3,15 03 x
3 60036035320 SHIM D=10/3,20 03 x
4 78036033000 VALVE COLLET LK 6H 16
5 61236032100 VALVE SPRING RETAINER 8
6 61236028100 VALVE SPRING NHK 8
7 59036027000 VALVE-STEM SEALING RACING 8
8 61236036100 VALVE SPRING HOLDER 8
9 61236030000 INTAKE VALVE D=42/6 (TI) 08 4
10 61236031000 EXHAUST VALVE D=34/6 (ST) 08 4
17
086123610 / C096123610
* NEW PART
X AS REQUIRED
Page 20
TIMING DRIVE
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 77336008010 HOLDING BOLT 2
2 0770010010 O-RING 10,00X1,00 NBR 70 SH 2
3* 61236008200 SCR. PLUG TIM. CHAIN TENS. KPL 2
4 0770220020 O-RING 22,00X2,00 B70 2
5 77036003000 CHAIN ADJUSTER HYD. 05 2
6 61236005000 GUIDE RAIL TOP 08 2
7 61236009000 CAMSHAFT INTAKE 08 1
8 61236010000 CAMSHAFT EXHAUST 08 1
9 61236109144 CAMSHAFT IN/RE CPL. 1
10 61236110000 CAMSHAFT EXHAUST 08 1
11 61236001000 GUIDE RAIL 08 2
12 61236002000 TENSIONER RAIL 08 2
13 61236013000 TIMING CHAIN 08 2
14 61230057000 IDLER GEAR L/S 1
15 0405151924 NEEDLE BEARING K 15X19X24ZW 1
16 61230057050 BEARING BOLT 15X57,5 08 1
17 61230057060 STOP DISK 15,2X25X1 2
18 61230157000 IDLER GEAR R/S 1
19 61236002050 COLLAR SCREW 08 4
20 0770034015 O-RING 34X1,5 VITON 1
21 61236080100 CENTRIFUGE CONE 1
22 61236081000 ANGLE PIECE F. BREATHER SYSTEM 1
23 0025060206 HH COLLAR SCREW M6X20 TX30 4
24* 0770180020 O-RING 18,00X2,00 NBR 70 2
18
096123620 / C096123620
* NEW PART
X AS REQUIRED
Page 21
CYLINDER HEAD REAR
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0984080305 AH SCREW DIN7984-M 8X30 10.9 6
2 0912060255 AH SCREW DIN0912-M 6X25 10.9 3
6 61236099100 VALVE COVER GASKET SET 1
7* 6123612010024 CYL.HEAD RC8 REAR 09 1
8 61230036000 CYLINDER HEAD GASGET 08 1
9 60011252000 TEMPERAT.-SENSOR WATER LC8 02 1
10 61036023100 VACUUM CONECTION 2006 1
11 0835080165 STUD M 8X16 10.9 3
13 60030063050 OIL JET 50 05 4
14 61236026000 VALVE GUIDE EXHAUST 08 2
15 61236025000 VALVE GUIDE INTAKE 08 2
16 0402050980 NEEDLE ROLLER DIN5402 5X9,8 2
17 61236082100 CONNECTING ANGLE 1
18 0770150151 O-RING 15,00X1,50 VITON 1
19 0770120020 O-RING 12,00X2,00 NBR 70 1
20* 6123615210033 VALVE COVER REAR 09 1
21 60036052020 COLLAR SCREW M 6 WS=10 03 4
22 61236075000 INSERT SPARK-PLUG SHAFT 08 1
23 0770298178 O-RING 29,87X1,78 VITON 2
24 61236079050 WASHER 11,1X20X3 08 4
25 61236079000 CYLINDER HEAD SCREW 08 4
27 61236044000 RUBBERSLEEVE INTAKE FLANGE 08 1
28 61236048000 HOSE CLAMP GEMI 66 / 1 1
29 0025060106 HH COLLAR SCREW M6X10 TX30 1
30 0603061001 CU-SEAL RING DIN7603-6X10X1 1
31 0125060003 WASHER DIN0125-A 6,4 2
32 0587060002 HH CAP NUT DIN1587-M 6 SS. 2
33 0770100020 O-RING 10,00X2,00 SILCONE 1
34 61235019100 WATER CONNECTION CPL. 1
35 0025060206 HH COLLAR SCREW M6X20 TX30 2
36 77336056095 SCREW PLUG 3
37 0770090015 O-RING 9X1,5 NBR 3
38* 69005005100 EXHAUST PIPE FLANGE GASKET 1
40* 0080060123 SCREW M6X12 ISA30 1
41* 61236082150 CONNECTING ANGLE RETAIN. PLATE 1
99* 61230097100 GASKET KIT CYLINDER+HEAD F+R 1
19
096123640 / C096123640
* NEW PART
X AS REQUIRED
Page 22
CYLINDER HEAD FRONT
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0912060255 AH SCREW DIN0912-M 6X25 10.9 3
2 61236099100 VALVE COVER GASKET SET 1
6* 6123605210033 VALVE COVER FRONT 09 1
7 60036052020 COLLAR SCREW M 6 WS=10 03 4
8 61236075000 INSERT SPARK-PLUG SHAFT 08 1
9 0770298178 O-RING 29,87X1,78 VITON 2
10 61236079000 CYLINDER HEAD SCREW 08 4
11 61236079050 WASHER 11,1X20X3 08 4
12 61236044000 RUBBERSLEEVE INTAKE FLANGE 08 1
13 61236048000 HOSE CLAMP GEMI 66 / 1 1
15 60030063050 OIL JET 50 05 4
16 60038091100 OIL-PRESSURE SWITCH LC8 04 1
17 0603061001 CU-SEAL RING DIN7603-6X10X1 1
18 0025060106 HH COLLAR SCREW M6X10 TX30 1
19 61230036000 CYLINDER HEAD GASGET 08 1
21 0835080165 STUD M 8X16 10.9 3
22* 6123602010024 CYLINDER HEAD FRONT 1
23 0402050980 NEEDLE ROLLER DIN5402 5X9,8 2
24 0984080305 AH SCREW DIN7984-M 8X30 10.9 6
25 61236026000 VALVE GUIDE EXHAUST 08 2
26 61236025000 VALVE GUIDE INTAKE 08 2
27 61036023100 VACUUM CONECTION 2006 1
28 60011252000 TEMPERAT.-SENSOR WATER LC8 02 1
29 0125060003 WASHER DIN0125-A 6,4 2
30 0587060002 HH CAP NUT DIN1587-M 6 SS. 2
31 0770100020 O-RING 10,00X2,00 SILCONE 1
32 0770090015 O-RING 9X1,5 NBR 3
33 61235019100 WATER CONNECTION CPL. 1
34 0025060206 HH COLLAR SCREW M6X20 TX30 2
35* 69005005100 EXHAUST PIPE FLANGE GASKET 1
36 77336056095 SCREW PLUG 2
99* 61230097100 GASKET KIT CYLINDER+HEAD F+R 1
20
086123650 / C096123650
* NEW PART
X AS REQUIRED
Page 23
LUBRICATING SYSTEM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0024060156 HH COLLAR SCREW M6X15 TX30 2
2 0024060206 HH COLLAR SCREW M6X20 TX30 1
4* 0770250030 O-RING 25,00X3,00 NBR 70 1
5 0770320020 O-RING 32,00X2,00 2
7* 61238085200 OILFILLTUBE CPL. 1
8 60030063070 OIL JET 70 M5 4
9 61238017000 OIL SCREEN BUSHING 08 2
10* 61238021100 OIL SCREEN CPL. 2
11 60038015000 OIL FILTER 03 1
13 0770140200 O-RING 14,00X2,00 2
16 0770125015 O-RING 12,5X1,5 NBR 2
17 0770170200 O-RING 17,00X2,00 2
19 61230065000 OIL INJECTION TUBE CPL. 08 1
20 0770010010 O-RING 10,00X1,00 NBR 70 SH 2
21 0025060256 HH COLLAR SCREW M6X25 TX30 1
22 0799080000 TAB WASHER DIN6799 RS8 1
23 60038007010 WASHER 10X16X0,5 03 2
24 60038001124 OIL PUMP GEAR 24-T 1
25 0402041580 NEEDLE ROLLER NRB 4X15,8 G2 4
26* 61238009144 PRESSURE PUMP COVER CPL. 1
27 60038028000 CONTROL PISTON LC8 03 1
29* 50337073000 SHIM 1
30 61238026000 CONTROL SPRING 1
31 60038009000 ROTOR-SET 19MM 03 1
32 61238002000 OIL PUMP SHAFT 08 1
33 61238011000 ROTOR-SET 22MM 08 1
34 61238010000 ROTOR-SET 30MM 08 1
35 61238008150 MOLDED RING SUCTION PUMP COVER 1
36* 61238008100 SUC. PUMP COVER CRANK CASE 09 1
37 0025060206 HH COLLAR SCREW M6X20 TX30 9
38 0402050980 NEEDLE ROLLER DIN5402 5X9,8 4
39 61238051000 MOLDED RING 1
40* 6123805000033 OIL COOLER CPL. 1
42 0025060506 HH COLLAR SCREW M6X50 TX30 1
43 61238052000 BUSHING 2
44 0770012021 O-RING 12X2 VITON GREEN 2
21
096123810 / C096123810
* NEW PART
X AS REQUIRED
Page 24
LUBRICATING SYSTEM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
46 61238055000 REGULATING SCREW 1
47 0770060020 O-RING 6,00X2,00 NBR 70 1
22
096123810 / C096123810
* NEW PART
X AS REQUIRED
Page 25
IGNITION SYSTEM
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 60039006000 STICK COIL 03 2
2 61239093200 SPARK PLUG M12X1,25 NGK R 08 2
3 60039040020 CABLE SUPPORT GENERATOR 03 1
4 0025050166 HH COLLAR SCREW M5X16 TX30 2
5 59039034000 PULSER COIL KOKUSAN 4K3-A/B 1
8 61239005000 FLYWHEEL CPL. 08 1
10 0025060256 HH COLLAR SCREW M6X25 TX30 3
11 61230040000 IGNITION COVER GASKET 08 1
12 49030090000 DOWEL 9,8 X 7 X 10 2
13 61239004000 STATOR 1
14* 6123000204441 IGNITION COVER WITH BEARING 1
15 0770024025 O-RING 24X2,5 NBR 1
16 6003009400030 SCREW PLUG M24X1,5 PA 6.6 1
17 61239003050 WASHER 12,5/25/3 1
18 61239003000 SCREW M12X1,5 1
19 80030058060 OIL JET "60" M4 1
20 0025060306 HH COLLAR SCREW M6X30 TX30 10
21 0025060356 HH COLLAR SCREW M6X35 TX30 2
23
086123910 / C096123910
* NEW PART
X AS REQUIRED
Page 26
ELECTRIC STARTER
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0985060003 SELF LOCK. NUT DIN0985-M 6 1
2 0125060003 WASHER DIN0125-A 6,4 1
3 61240001000 E-STARTER ENGINE 9T 08 1
4 0618101410 NEEDLE SLEEVE HK 1010 10/14/10 1
5 60038007010 WASHER 10X16X0,5 03 1
9 0625060016 GROOV.BALL BEAR. 6001.2RSR C3 1
10 61240017100 TORQUE LIMITER 10/45 CPL. 1
14 61230058050 BEARING BOLT 15X39 08 1
15 0405151913 NEEDLE BEARING K 15X19X13 1
16 61240022100 INTERMEDIATE GEAR 43T 1
17 61230057060 STOP DISK 15,2X25X1 2
18 0618354220 NEEDLE BUSH HK3520 35/42/20 1
21 61239005000 FLYWHEEL CPL. 08 1
22 0984060203 AH SCREW DIN6912-M 6X20 8.8 8
23* 61240020300 FREEWHEEL GEAR 66-T 1
24 0025060256 HH COLLAR SCREW M6X25 TX30 2
25 60040027000 FREEWHEEL HOLDER 03 1
26 60040027050 SUPPORTING SLEEVE 03 2
27 0025060306 HH COLLAR SCREW M6X30 TX30 2
28 0770335030 O-RING 33,5X3 VITON 1
24
086124010 / C096124010
* NEW PART
X AS REQUIRED
Page 27
THROTTLE BODY
1190 RC8 2009
FIG PART NUMBER DESCRIPTION QTY
1 0081500181 SCREW FOR PLASTIC D=5X18 2
2 61041080000 AMBIENT-AIR TEMPERATURE SENSOR 1
3 61041085150 RUBBER SUPP. PRESSURE SENS. 06 3
4 61041085100 PRESSURE SENSOR 06 3
5 61036023100 VACUUM CONECTION 2006 2
6 60031098001 HOSE 3,2X8,5 PER METER x
8 61241040000 INTAKE TRUMPET 08 2
9 61241001000 THROTTLE BODY CPL. DK52 1
10 69006001031 SENSOR-RETAIN. PLATE AIRBOX 08 1
11 69006001032 HOLDER WIRING HARNESS REAR 1
12 0081050161 EJOT PT SCREW K50X16 1451 4
13 61041031200 TIMING CHARGER EFI 08 1
14 60039030000 VIBRATION DAMPER DIGITALBOX 03 2
15 0021050003 WASHER DIN9021-A 5,3 2
17 0912040203 AH SCREW DIN 912-M 4X20 2
18 61041088050 SHIM 4,3X15X1,25MM GALVANIZED 2
19 61041088000 ROLLOVER SENSOR 05 1
20 0024060106 HH COLLAR SCREW M6X10 TX30 1
21 69041088050 HOLDER ROLLOVER SENSOR 1
22 75041023020 O-RING 3
23 75041023010 SEAL RING 2
24 61241023044 INJECTOR CPL. 2
25 61241013044 FUEL HOSE CPL. 1
27 75041013060 SCREW SHOULDER 2
28 61041060040 SCREW FOR SUPPORT STEPPER MOT. 1
25
086124110 / C096124110
* NEW PART
X AS REQUIRED
Page 28
1190 RC8 2009
Page 29
1190 RC8 2009
Page 30
1190 RC8 2009
Page 31
Page 32
Art.Nr.: 3CM089850IEN 9/2008
www.ktm.at
A-5230 Mattighofen
KTM-Sportmotorcycle AG
KTM Group Partner
3CM089850IEN
*3CM089850IEN*
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