KTM 1190 RC8 R 2012 Owner's manual
OWNER'S MANUAL 2012
1190 RC8 R EU/UK
1190 RC8 R FR
1190 RC8 R JP
Art. no. 3211785en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
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 a lot of enjoyment in 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. 16)
Key number ( p. 17)
The owner's manual contained the latest information for this model at the time of going to print. 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 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
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side (vehicle differs slightly from
photo) ............................................................................. 12
View of vehicle, rear right side (vehicle differs slightly from
photo) ............................................................................. 14
SERIAL NUMBERS............................................................... 16
Vehicle identification number/type label ............................. 16
Engine number................................................................. 16
Key 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
Throttle grip..................................................................... 20
Light switch..................................................................... 20
Headlight flasher switch .................................................... 21
Turn signal switch ............................................................ 21
Horn button ..................................................................... 22
Emergency OFF switch ...................................................... 22
Electric starter button ....................................................... 23
Ignition/steering lock ........................................................ 23
Immobilizer ..................................................................... 24
Combination instrument - overview..................................... 25
Combination instrument - function buttons on handlebar ..... 26
Combination instrument - activation and test ...................... 27
Display............................................................................ 28
Info display...................................................................... 29
Indicator lamps ................................................................ 30
Notes/warnings on the combination instrument.................... 31
Overview of ROAD mode.................................................... 34
Distance menu 1, ODO/Trip 1/Time 1/Avs 1 ........................ 35
Distance menu 2, ODO/Trip 2/Time 2/Avs 2 ........................ 36
Gear display menu, ODO/Trip 1/Gear .................................. 37
Fuel and external temperature menu, FUEL ........................ 39
Mapping menu, ENGINE MAP ........................................... 40
Next service menu, DISTANCE TO Next Service................... 41
Overview of RACE mode .................................................... 42
Remaining laps menu, LAPSTOGO ..................................... 43
Maximum lap speed menu, TOPSPEED .............................. 44
Gear display menu, LastLap/RaceTrip/Gear ......................... 46
Fuel and external temperature menu, FUEL ........................ 47
Mapping menu, ENGINE MAP ........................................... 48
Lap times menu, LAP/BESTLAP/LapTime ........................... 49
Maximum speed menu, LAP/BESTLAP/TopSpeed ................ 50
Total distance in Race mode menu, RACEODO.................... 51
Overview of SET‑UP mode ................................................. 52
SET‑UP menu .................................................................. 54
Mode menu, CHANGE MODE ............................................ 55
Time menu, SET CLOCK ................................................... 56
SETTINGS menu .............................................................. 57
Shift warning lamp menu, SHIFT RPMS ............................. 58
LAP button blank time, LAP BLANK TIME menu ................. 59
Number of laps menu, SET NUM LAPS .............................. 60
Fuel reserve display menu, TRIP F RESET .......................... 61
TABLE OF CONTENTS 4
UNITS menu.................................................................... 62
Kilometers/miles menu, SET KM/MILES ............................. 64
Temperature display menu, SET °C/°F ................................ 65
Fuel consumption menu (liters), SET FUEL CONS ............... 66
Fuel consumption menu (gallons), SET GAL US/UK ............. 67
Additional functions menu, OPTIONS ................................. 68
Quick shifter menu, OPTION QKSHIFT ............................... 69
External temperature display menu, OPTION OUTTEMP....... 70
Tire pressure monitor menu, OPTION TPMS........................ 71
Adjusting the mapping of the engine electronics
ENGINE MAP................................................................... 80
Displaying lap times ......................................................... 81
Displaying maximum speed ............................................... 81
Setting ROAD or RACE mode ............................................. 82
Setting the clock with SET CLOCK ..................................... 83
Adjusting the shift speed RPM1/2...................................... 83
Setting the blank time of the LAP button
LAP BLANK TIME ............................................................ 85
Setting the number of laps SET NUM LAPS ........................ 86
Setting the fuel reserve display TRIP F RESET .................... 87
Setting the kilometers/miles SET KM/MILES ....................... 88
Setting the temperature unit SET °C/°F .............................. 89
Setting the unit of fuel consumption (liters)
SET FUEL CONS.............................................................. 90
Unit of fuel consumption (gallons) SET GAL US/UK............. 91
Switching the external temperature display on/off ................ 92
Opening the filler cap ....................................................... 93
Closing the filler cap ......................................................... 95
Tool set ........................................................................... 95
Supporting strap............................................................... 96
Passenger footrests........................................................... 96
Shift lever........................................................................ 97
Foot brake lever................................................................ 98
Side stand ....................................................................... 98
Seat lock ......................................................................... 99
Helmet lock ..................................................................... 99
PREPARING FOR USE ........................................................ 100
Advice on first use.......................................................... 100
Running the engine in..................................................... 101
Loading the vehicle ........................................................ 101
RIDING INSTRUCTIONS ..................................................... 104
Checks and maintenance measures when preparing for
use ............................................................................... 104
Starting ......................................................................... 105
Starting off .................................................................... 106
Shifting, riding............................................................... 107
Braking ......................................................................... 110
Stopping, parking ........................................................... 111
Refueling....................................................................... 112
SERVICE SCHEDULE.......................................................... 115
Service schedule ............................................................ 115
TUNING THE CHASSIS....................................................... 118
Fork/shock absorber........................................................ 118
Adjusting the compression damping of the fork ................. 118
Adjusting the rebound damping of the fork........................ 119
Adjusting the spring preload of the fork ............................ 120
Compression damping of the shock absorber ..................... 121
Adjusting the low-speed compression damping of the
shock absorber............................................................... 122
TABLE OF CONTENTS 5
Adjusting the high-speed compression damping of the
shock absorber............................................................... 123
Adjusting the rebound damping of the shock absorber........ 124
Adjusting the spring preload of the shock absorber x ....... 124
Steering damper............................................................. 126
Adjusting the steering damper ......................................... 127
Vehicle level .................................................................. 128
Adjusting front vehicle level x........................................ 129
Adjusting the vehicle level at the rear ............................... 131
Footrest position............................................................. 132
Adjusting the footrest position ......................................... 132
Adjusting shift lever stub................................................. 135
Adjusting the foot brake lever stub ................................... 136
Adjusting shift lever ........................................................ 136
Adjusting the foot brake lever .......................................... 140
Checking free travel of foot brake lever ............................. 140
Handlebar height/position ............................................... 141
Adjusting the handlebar height/position ............................ 142
Rear frame position ........................................................ 147
Adjusting the rear frame position ..................................... 148
SERVICE WORK ON THE CHASSIS ...................................... 153
Raising the front of the motorcycle with lifting gear ........... 153
Taking the motorcycle off of the front wheel stand ............. 153
Raising the rear of the motorcycle with lifting gear............. 154
Removing the rear of motorcycle from the lifting gear......... 154
Bleeding fork legs........................................................... 155
Removing the seat.......................................................... 155
Fitting the seat............................................................... 156
Mounting the helmet lock on the vehicle........................... 156
Removing the passenger seat........................................... 157
Mounting the passenger seat ........................................... 157
Checking for chain dirt.................................................... 158
Cleaning the chain.......................................................... 158
Checking the chain tension ............................................. 159
Adjusting the chain tension ............................................. 160
Checking the chain, rear sprocket and engine sprocket....... 162
Adjusting basic position of clutch lever............................. 165
Checking fluid level of hydraulic clutch ............................ 165
Correcting fluid level of hydraulic clutch ........................... 166
BRAKES............................................................................ 167
Adjusting the basic position of the hand brake lever........... 167
Checking the front brake discs ......................................... 167
Checking the rear brake disc............................................ 168
Checking the front brake fluid level .................................. 169
Adding brake fluid of front brake x................................. 169
Checking the front brake linings....................................... 171
Checking the rear brake fluid level ................................... 172
Adding rear brake fluid x .............................................. 173
Checking the rear brake linings ........................................ 174
WHEELS, TIRES ................................................................ 176
Removing the front wheel x........................................... 176
Installing the front wheel x............................................ 177
Removing the rear wheel x ............................................ 180
Installing the rear wheel x............................................. 181
Checking rear hub cush drive x...................................... 183
Checking the tire condition.............................................. 184
Checking the tire pressure ............................................... 186
TABLE OF CONTENTS 6
ELECTRICAL SYSTEM ........................................................ 188
Removing the battery x................................................. 188
Installing the battery x.................................................. 190
Recharging the battery x............................................... 191
Changing the main fuse .................................................. 194
Changing the fuses of individual power consumers............. 196
Changing the low beam bulb............................................ 198
Changing the high beam bulb .......................................... 201
Checking the headlight setting......................................... 204
Adjusting the headlight range .......................................... 204
Activating/deactivating ignition key .................................. 205
COOLING SYSTEM ............................................................. 209
Cooling system............................................................... 209
Checking the coolant level............................................... 209
Filling cooling system compensating tank ......................... 210
TUNING THE ENGINE ........................................................ 212
Checking the play in the throttle cable.............................. 212
Adjusting the play in the throttle cable x ........................ 213
SERVICE WORK ON THE ENGINE ....................................... 214
Checking the engine oil level ........................................... 214
Changing engine oil and filter, cleaning oil screen x ........ 215
Draining engine oil, cleaning oil screens x ...................... 215
Removing the oil filter x................................................ 218
Installing the oil filter x ................................................ 220
Filling up with engine oil x............................................ 220
Adding engine oil ........................................................... 222
CLEANING, CARE .............................................................. 224
Cleaning motorcycle ....................................................... 224
Checks and maintenance steps for winter operation ........... 225
STORAGE .......................................................................... 227
Storage.......................................................................... 227
Putting into operation after storage .................................. 228
TROUBLESHOOTING.......................................................... 229
IMMOBILIZER BLINK CODE................................................ 232
ENGINE CONTROL BLINK CODE ......................................... 234
TECHNICAL DATA - ENGINE ............................................... 240
Capacity - engine oil ....................................................... 241
Capacity - coolant........................................................... 242
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 243
TECHNICAL DATA - CHASSIS ............................................. 246
Lighting equipment ........................................................ 247
Tires ............................................................................. 248
Capacity - fuel................................................................ 248
TECHNICAL DATA - FORK................................................... 249
TECHNICAL DATA - SHOCK ABSORBER .............................. 250
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 252
SUBSTANCES.................................................................... 255
AUXILIARY SUBSTANCES................................................... 259
STANDARDS...................................................................... 261
INDEX ............................................................................... 262
MEANS OF REPRESENTATION 7
Symbols used
The symbols used are explained below.
Indicates an expected reaction (e.g. to a work step or a function).
Indicates an unexpected reaction (e.g. to a work step or a function).
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 optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a trademark.
Identifies a protected name.
IMPORTANT INFORMATION 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.
Service
A prerequisite for fault-free operation and avoiding premature wear is compliance with the service, 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.
Make sure to comply with the specified run-in times and service intervals. Close adherence to these periods will significantly lengthen the
service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. 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 INFORMATION 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 may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– 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.
– 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 INFORMATION 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 potential hazards and may therefore be injured.
IMPORTANT INFORMATION 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 learn how to best customize the motorcycle for your own use and how
to 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
3.1View of vehicle, front left side (vehicle differs slightly from photo)
C00127-10
VIEW OF VEHICLE 13
1 Clutch lever ( p. 19)
2 Light switch ( p. 20)
2 Headlight flasher switch ( p. 21)
2 Turn signal switch ( p. 21)
2 Horn button ( p. 22)
3 Filler cap
4 Seat lock ( p. 99)
5 Oil dipstick
6 Side stand ( p. 98)
7 Shift lever ( p. 97)
8 Passenger footrests ( p. 96)
VIEW OF VEHICLE 14
3.2View of vehicle, rear right side (vehicle differs slightly from photo)
B00567-10
VIEW OF VEHICLE 15
1 Passenger seat
2 Supporting strap ( p. 96)
3 Rear mirror
4 Combination instrument
5 Emergency OFF switch ( p. 22)
5 Electric starter button ( p. 23)
6 Hand brake lever ( p. 19)
7 Vehicle identification number/type label ( p. 16)
8 Shock absorber rebound adjustment
9 Foot brake lever ( p. 98)
10 Engine number ( p. 16)
11 Fork compression adjustment
SERIAL NUMBERS 16
4.1Vehicle identification number/type label
The vehicle identification number 1 is stamped on the frame behind the steering head on
the right.
The type label 2 is on the frame above the vehicle identification number.
100654-10
4.2Engine number
The engine number 1 is stamped on the right side of the engine.
100655-10
SERIAL NUMBERS 17
4.3Key number
The key number Code number 1 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
4.4Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
B00590-10
SERIAL NUMBERS 18
4.5Shock absorber part number
The shock absorber part number 1 is stamped on the upper part of the shock absorber
above the adjusting ring towards the rear.
100657-10
4.6Steering damper part number
The steering damper part number 1 is stamped on the top of the steering damper.
100658-10
CONTROLS 19
5.1Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulic and self-adjusting.
100659-10
5.2Hand brake lever
The hand brake lever 1 is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
100660-10
CONTROLS 20
5.3Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
B00568-10
5.4Light switch
The light switch 1 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
CONTROLS 21
5.5Headlight flasher switch
The headlight flasher switch 1 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
5.6Turn signal switch
The turn signal switch 1 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.
100661-11
To switch off the turn signal, press the turn signal switch towards the switch housing.
CONTROLS 22
5.7Horn button
The horn button 1 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
5.8Emergency OFF switch
The emergency OFF switch 1 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.
100664-10
CONTROLS 23
5.9Electric starter button
The electric starter button 1 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
5.10Ignition/steering lock
The ignition/steering lock 1 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 – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The black ignition
100663-10
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.
CONTROLS 24
5.11Immobilizer
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.
400679-10
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 25
5.12Combination instrument - overview
1 Display ( p. 28)
2 Function buttons
3 Indicator lamps ( p. 30)
4 Info display ( p. 29)
401121-10
CONTROLS 26
5.13Combination instrument - function buttons on handlebar
The MODE button 1 is fitted on the handlebar, front left.
The LAP button 2 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. Clocks the lap times in RACE
mode.
100665-10
CONTROLS 27
5.14Combination instrument - activation and test
Activation
The combination instrument is activated when the ignition is switched on.
Test
The segments of the tachometer and the gear display 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.
The display then changes to the last selected mode.
401120-01
CONTROLS 28
5.15Display
The tachometer 1 displays the engine speed in revolutions per minute (RPM).
The red marking 2 marks the over-rev (excessive speed) range of the engine.
The gear display 3 shows the engaged gear.
Info
The engaged gear can also be displayed in the info display.
The speed 4 is displayed in kilometers per hour KM/H or in miles per hour MPH.
The time appears in segment 5.
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 6.
The info display 7 shows additional information.
401121-12
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