KTM 1190 RC8 R Manual

OWNER'S MANUAL 2009

1190 RC8 R EU/UK

1190 RC8 R AUS

1190 RC8 R FR

1190 RC8 R JP

ART. NO. 3211375en

DEAR KTM CUSTOMER

1

We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you a great deal of pleasure during your ownership if you service and maintained it accordingly.

We hope you will derive pleasure from riding this vehicle.

Please enter the serial numbers of your vehicle below.

Vehicle identification number/type label ( p. 16)

Dealer's stamp

Engine number ( p. 17)

Key number ( p. 16)

The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.

All specifications are non-binding. KTM Sportmotorcycle AG specifically 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 misprints and other errors. The models portrayed partly contain special equipment that does not form part of the regular scope of delivery.

DEAR KTM CUSTOMER

2

© 2009 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)

According to 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
Vehicle identification number/type label .............................	16
Key number .....................................................................	16
Engine number.................................................................	17
Fork part number..............................................................	17
Shock absorber part number..............................................	18
Steering damper part number ............................................	18
CONTROLS ..........................................................................	19
Clutch lever .....................................................................	19
Hand brake lever ..............................................................	19
Light switch .....................................................................	20
Headlight flasher switch....................................................	20
Turn signal switch ............................................................	21
Horn button .....................................................................	21
Ignition/steering lock ........................................................	22
Emergency OFF switch......................................................	22
Electric starter button .......................................................	23
immobilizer......................................................................	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
Odometer menu ODO/Trip 1 ..............................................	33
Odometer menu ODO/Trip 2 ..............................................	34
FUELDISTANCE menu......................................................	35
FUELRANGE menu...........................................................	36
DISTANCE TO Next Service menu ......................................	37
LAPSTOGO menu .............................................................	38
TOPSPEED menu .............................................................	39
LAP/BESTLAP/LastLap menu.............................................	40
LAP/BESTLAP/TopSpeed menu..........................................	41
Total distance menu in Race mode RACEODO.....................	42
SET UP menu ..................................................................	43
CHANGE MODE menu ......................................................	44
SET CLOCK menu ............................................................	45
SETTINGS menu ..............................................................	46
SHIFT RPMS menu ..........................................................	47
LAP menu, LAP BLANK T button .......................................	48
SET NUM LAPS menu ......................................................	49
TRIP F RESET menu ........................................................	50
UNITS menu....................................................................	51
SET KM/MILES menu .......................................................	52
SET °C/°F menu ...............................................................	53
OPTIONS menu................................................................	54
TPMS menu.....................................................................	55
OUTERTEMP menu ..........................................................	56
Displaying lap times .........................................................	61
Displaying maximum speed ...............................................	62
Setting ROAD or RACE mode.............................................	63
Setting the clock with SET CLOCK .....................................	63

CONTENTS

4

Adjusting shift speed RPM1/2 ...........................................	64
Setting the blank time of the LAP button LAP BLANK T.......	65
Setting the number of laps SET NUM LAPS ........................	67
Setting the fuel reserve display TRIPF RESET .....................	68
Setting the kilometers/miles SET KM/MILES .......................	69
Setting the temperature unit SET °C/°F ..............................	70
Switching the external temperature display on/off ................	70
Opening the filler cap .......................................................	72
Closing the filler cap.........................................................	73
Supporting strap...............................................................	73
Seat lock .........................................................................	74
Tool set ...........................................................................	74
Helmet lock .....................................................................	75
Passenger footrests...........................................................	75
Shift lever........................................................................	76
Foot brake pedal ..............................................................	77
Side stand .......................................................................	77
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION.........................................................................	78
advice on first use ............................................................	78
Running the engine in.......................................................	79
Loading the vehicle ..........................................................	80
RIDING INSTRUCTIONS .......................................................	82
Checks to be made before putting into operation .................	82
Starting ...........................................................................	83
Starting up ......................................................................	84
Shifting, riding.................................................................	85
Braking ...........................................................................	88
Stopping, parking .............................................................	89

Refueling.........................................................................	90
SERVICE SCHEDULE............................................................	92
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. .........................................................	92
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. (as additional job) ..............................	95
MAINTENANCE WORK ON FRAME AND ENGINE....................	96
Jacking up motorcycle front...............................................	96
Taking front of motorcycle off work stand............................	96
Jacking up motorcycle rear ................................................	97
Taking rear of motorcycle off work stand .............................	97
Fork/shock absorber..........................................................	98
Adjusting the compression damping of the fork ...................	98
Adjusting the rebound damping of the fork..........................	99
Adjusting the spring preload of the fork ............................	100
Bleeding fork legs...........................................................	101
Compression damping of the shock absorber .....................	102
Adjusting the low-speed compression damping of the
shock absorber ...............................................................	102
Adjusting the high-speed compression damping of the
shock absorber ...............................................................	103
Adjusting the rebound damping of the shock absorber........	104
Adjusting the spring preload of the shock absorber x.......	105
Steering damper.............................................................	107
Adjusting the steering damper .........................................	107
Vehicle level ..................................................................	109
Adjusting front vehicle level x........................................	110
Adjusting the vehicle level at the rear ...............................	112
Footrest position.............................................................	113
Adjusting footrest position...............................................	113

CONTENTS

5

Adjusting shift lever stub.................................................	116
Adjusting shift lever........................................................	116
Adjusting the footbrake pedal stub ...................................	120
Adjusting the footbrake pedal ..........................................	121
Checking for chain dirt....................................................	122
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 the front brake discs.........................................	128
Checking the rear brake disc............................................	129
Adjusting the basic position of the handbrake lever............	130
Checking the front brake fluid level ..................................	131
Topping up brake fluid of front brake x...........................	131
Brake linings..................................................................	133
Checking the front brake linings.......................................	133
Checking rear brake fluid level.........................................	134
Adding rear brake fluid x..............................................	135
Checking the rear brake linings ........................................	136
Removing the front wheel x...........................................	137
Installing the front wheel x............................................	139
Removing the rear wheel x............................................	141
Installing the rear wheel x.............................................	142
Checking rear hub cush drive x......................................	144
Checking the tire condition..............................................	145
Checking the tire pressure ...............................................	147
Removing the seat ..........................................................	148

Fitting the seat...............................................................	148
Removing the passenger seat...........................................	149
Mounting the passenger seat ...........................................	149
Mounting the helmet lock on the vehicle...........................	150
Removing the battery x.................................................	150
Installing the battery x..................................................	152
Recharging the battery x...............................................	154
Changing the main fuse ..................................................	156
Changing the fuses of individual power consumers.............	158
Changing the low beam bulb............................................	160
Changing the high beam lamp .........................................	163
Changing the parking light bulb .......................................	166
Checking the headlamp setting ........................................	168
Adjusting headlamp range ...............................................	169
Activating/deactivating ignition key ..................................	169
Cooling system ...............................................................	173
Checking the coolant level...............................................	173
Filling the cooling system compensating tank....................	174
Adjusting basic position of clutch lever.............................	176
Checking fluid level of hydraulic clutch ............................	176
Correcting fluid level of hydraulic clutch...........................	177
Adjusting the play in the throttle cable x........................	178
Throttle grip...................................................................	178
Handlebar height............................................................	179
Adjusting the handlebar height ........................................	179
Rear frame position ........................................................	182
Adjusting the rear frame position .....................................	182
Checking the engine oil level ...........................................	187
Changing engine oil and filter, cleaning oil screen x........	187

CONTENTS			6
Draining engine oil, cleaning oil screens x......................	188	INDEX ...............................................................................	234
Removing the oil filter x................................................	191
Installing the oil filter x................................................	193
Filling up with engine oil x............................................	193
Adding engine oil ...........................................................	195
TROUBLESHOOTING..........................................................	197
IMMOBILIZER BLINK CODE................................................	200
ENGINE CONTROL BLINK CODE.........................................	202
CLEANING.........................................................................	208
Cleaning motorcycle .......................................................	208
PROTECTIVE TREATMENT FOR WINTER OPERATION...........	210
Conservation for winter operation .....................................	210
STORAGE ..........................................................................	211
Storage..........................................................................	211
Putting into operation after storage ..................................	212
TECHNICAL DATA - ENGINE...............................................	213
Capacityengine oil ........................................................	214
Capacity - coolant...........................................................	214
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	215
TECHNICAL DATA - FRAME ................................................	218
Lighting equipment ........................................................	219
Tires .............................................................................	220
Capacity - fuel................................................................	220
TECHNICAL DATA - FORK...................................................	221
TECHNICAL DATA - SHOCK ABSORBER ..............................	222
TECHNICAL DATA - FRAME TIGHTENING TORQUES ............	224
SUBSTANCES....................................................................	227
AUXILIARY SUBSTANCES...................................................	231
STANDARDS......................................................................	233

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 owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of 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. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached. Pay careful attention to the prescribed running-in period and inspection and maintenance intervals. Close adherence to these periods will significantly lengthen the service life of your motorcycle.

Warranty

The work described in the service schedule 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

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.

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

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000)

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 thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions 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 repairs or servicing, the vehicle must be checked for roadworthiness.

Transport

Note

Danger of damage The parked vehicle can roll away or fall over.

–Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components get very hot when the machine is driven.

–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first.

–Switch off the engine and remove the ignition key.

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

IMPORTANT NOTES

10

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.

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 sources of danger and may therefore be injured.

IMPORTANT NOTES

11

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

–Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to help you operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

	VIEW OF VEHICLE	12
	View3.1 of vehicle, front left side

100652-10

	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

100653-10

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

Vehicle4.1 identification number/type label

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

The type label is on the frame above the vehicle identification number.

100654-10

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.

100655-10

Fork4.4 part number

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

100656-10

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.

100657-10

Steering4.6 damper part number

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

100658-10

CONTROLS

19

Clutch5.1 lever

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

The clutch is hydraulic and self-adjusting.

100659-10

Hand5.2 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

CONTROLS

20

Light5.3 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.

High beam on – The light switch is in the upper position. In this position, the low beam, the high beam and the tail light are switched on.

100661-10

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.

100662-10

CONTROLS

21

Turn5.5 signal switch

100661-11

The turn signal switch is fitted on the left side of the handlebar.

Possible states

Turn signal off

Left turn signal on – The turn signal switch is pressed to the left. The turn signal switch automatically returns to the central position after use.

Right turn signal on – The turn signal switch is pressed to the right. The turn signal switch automatically returns to the central position after use.

To switch off the turn signal, press the turn signal switch towards the switch housing.

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.

100661-12

CONTROLS

22

Ignition/steering5.7 lock

100663-10

Emergency5.8 OFF switch

100664-10

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

Info

The ignition may only be switched on using a black ignition key.

Use the orange programming key to activate and deactivate the black ignition key.

Possible states

Ignition off 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.

Switch on the 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.

The emergency OFF switch is installed 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.

CONTROLS

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.

100664-11

immobilizer5.10

400679-10

The electronic immobilizer secures the vehicle against unauthorized use.

The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn.

The red warning lamp flashes at 15 second intervals after one minute. The red warning lamp can also indicate errors by flashing.

Info

The ignition key contains electronic components. Never attach multiple ignition keys to a single key ring; this may cause mutual interference and lead to problems.

A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle.

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.

CONTROLS

24

Combination5.11 instrument - overview

1Display ( p. 27)

2Function buttons

3Indicator lamps ( p. 29)

4Info display ( p. 28)

400580-10

	CONTROLS			25
	Combination5.12	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.
			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 in the info display in ROAD mode. Clocks the lap times in RACE mode.

100665-10

	CONTROLS			26
	Combination5.13	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, Trip 1, Time 1, Avs 1 mode.
			In RACE mode, the info display switches to LAPSTOGO, LastLap, ±Last, ±Best mode.

400429-10

	CONTROLS	27
	Display5.14
			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.

400580-12

	CONTROLS				28
	Info5.15	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 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.
				Information repeat		45 s

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

400580-13