KTM 1190 RC8 USA Manual

4.5 (2)

OWNER'S MANUAL 2008

1190 RC8 USA

ART. NO. 3211307en

DEAR KTM 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 great pleasure riding the vehicle!

Please enter the serial numbers of your vehicle below.

Chassis number/type label ( p. 24)

Dealer's stamp

Engine number ( p. 25)

Key number ( p. 24)

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 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 printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER

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

MEANS OF REPRESENTATION ...............................................	7
IMPORTANT NOTES...............................................................	8
Overview of labels.............................................................	10
VIEW OF VEHICLE................................................................	20
View of vehicle, front left side............................................	20
View of vehicle, rear right side ...........................................	22
LOCATION OF SERIAL NUMBERS .........................................	24
Chassis number/type label.................................................	24
Key number .....................................................................	24
Engine number.................................................................	25
Fork part number..............................................................	25
Shock absorber part number..............................................	26
Steering damper part number ............................................	26
CONTROLS ..........................................................................	27
Clutch lever .....................................................................	27
Hand brake lever ..............................................................	27
Light switch .....................................................................	28
Headlight flasher switch....................................................	28
Flasher switch..................................................................	29
Horn button .....................................................................	29
Ignition/steering lock ........................................................	30
Emergency OFF switch......................................................	30
Electric starter button .......................................................	31
Combination instrument - overview.....................................	32
Combination instrument - function buttons on handlebar .....	33
Combination instrument - activation and test ......................	34
Display ............................................................................	35
Info display......................................................................	36
Indicator lamps ................................................................	37

Notes/warnings on the combination instrument....................	38
ODO menu.......................................................................	41
FUELDISTANCE menu......................................................	42
FUELRANGE menu...........................................................	43
DISTANCE TO Next Service menu ......................................	44
LAPSTOGO menu .............................................................	45
TOPSPEED menu .............................................................	46
LAP/BESTLAP/LastLap menu.............................................	47
LAP/BESTLAP/TopSpeed menu..........................................	48
Total distance menu in Race mode RACEODO.....................	49
SET UP menu ..................................................................	50
CHANGE MODE menu ......................................................	51
SET CLOCK menu ............................................................	52
SETTINGS menu ..............................................................	53
SHIFT RPMS menu ..........................................................	54
LAP menu, LAP BLANK T button .......................................	55
SET NUM LAPS menu ......................................................	56
TRIP F RESET menu ........................................................	57
UNITS menu....................................................................	58
SET KM/MILES menu .......................................................	59
SET °C/°F menu ...............................................................	60
OPTIONS menu................................................................	61
TPMS menu.....................................................................	62
OUTERTEMP menu ..........................................................	63
Displaying lap times .........................................................	68
Displaying maximum speed ...............................................	69
Setting ROAD or RACE mode.............................................	70
Setting the clock with SET CLOCK .....................................	70
Adjusting shift speed RPM1/2 ...........................................	71

CONTENTS

Setting the blank time of the LAP button LAP BLANK T.......	72
Setting the number of laps SET NUM LAPS ........................	74
Setting the fuel reserve display TRIPF RESET .....................	75
Setting the kilometers/miles SET KM/MILES .......................	76
Setting the temperature unit SET °C/°F ..............................	77
Switching the external temperature display on/off ................	77
Opening the filler cap .......................................................	79
Closing the filler cap.........................................................	80
Supporting strap...............................................................	80
Seat lock .........................................................................	81
Helmet lock .....................................................................	81
Passenger footrests...........................................................	82
Shift lever........................................................................	82
Foot brake pedal ..............................................................	83
Side stand .......................................................................	84
TIPS ON PUTTING INTO OPERATION ....................................	85
Advice on first use............................................................	85
Running the engine in.......................................................	86
Loading the vehicle ..........................................................	87
RIDING INSTRUCTIONS .......................................................	89
Checks to be made before putting into operation .................	89
Starting ...........................................................................	90
Starting up ......................................................................	91
Shifting, riding.................................................................	92
Braking ...........................................................................	95
Stopping, parking .............................................................	96
Refueling.........................................................................	97

SERVICE SCHEDULE............................................................	99
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. .........................................................	99
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. (as additional job) ............................	102
MAINTENANCE WORK ON CHASSIS AND ENGINE...............	103
Jacking up motorcycle front.............................................	103
Taking front of motorcycle off work stand..........................	103
Jacking up motorcycle rear ..............................................	104
Taking rear of motorcycle off work stand ...........................	104
Fork/shock absorber........................................................	105
Adjusting compression damping of fork ............................	105
Adjusting rebound damping of fork...................................	106
Adjusting spring preload of fork .......................................	107
Bleeding fork legs...........................................................	108
Compression damping of the shock absorber .....................	109
Adjusting the low-speed compression damping of the
shock absorber ...............................................................	109
Adjusting high-speed compression damping of the shock
absorber ........................................................................	111
Adjusting rebound damping of the shock absorber .............	112
Adjusting spring preload of shock absorber x..................	112
Steering damper.............................................................	115
Adjusting the steering damper .........................................	115
Vehicle level ..................................................................	117
Adjusting front vehicle level x........................................	118
Adjusting the vehicle level at the rear ...............................	120
Footrest position.............................................................	122
Adjusting footrest position...............................................	122
Adjusting shift lever stub.................................................	124

CONTENTS

Adjusting shift lever........................................................	124
Adjusting the footbrake pedal stub ...................................	128
Adjusting the footbrake pedal ..........................................	129
Checking for chain dirt....................................................	129
Cleaning the chain..........................................................	130
Checking the chain tension .............................................	131
Adjusting the chain tension .............................................	132
Checking rear sprocket / engine sprocket for wear ..............	134
Checking chain wear.......................................................	135
Checking chain sliding guard ...........................................	136
Checking the front brake discs.........................................	136
Checking the rear brake disc............................................	137
Adjusting the basic position of the handbrake lever............	137
Checking brake fluid level of front brake ...........................	138
Topping up brake fluid of front brake x...........................	138
Brake linings..................................................................	140
Checking the front brake linings.......................................	140
Checking rear brake fluid level.........................................	141
Topping up rear brake fluid x........................................	142
Checking the rear brake linings ........................................	143
Removing front wheel x................................................	144
Fitting front wheel x.....................................................	145
Removing rear wheel x..................................................	146
Installing the rear wheel x.............................................	148
Checking rear hub shock absorbers x.............................	151
Tire condition checking...................................................	151
Checking tire air pressure................................................	153
Removing the seat ..........................................................	154
Fitting the seat...............................................................	154

Removing passenger seat ................................................	155
Fitting the passenger seat ...............................................	155
Mounting helmet lock on vehicle......................................	156
Removing the battery x.................................................	156
Installing the battery x..................................................	158
Recharging the battery x...............................................	159
Changing the main fuse ..................................................	161
Changing the fuses of individual power consumers.............	163
Changing the low beam bulb............................................	165
Changing the high beam bulb ..........................................	168
Changing the parking light bulb .......................................	172
Checking headlight adjustment ........................................	175
Adjusting headlamp range ...............................................	175
Activating/deactivating ignition key ..................................	176
Cooling system ...............................................................	179
Checking the coolant level...............................................	180
Filling the cooling system compensating tank....................	181
Adjusting basic position of clutch lever.............................	183
Checking fluid level of hydraulic clutch ............................	183
Correcting fluid level of hydraulic clutch...........................	184
Adjusting gas Bowden cable x.......................................	185
Handlebar height............................................................	185
Adjusting the handlebar height ........................................	186
Rear frame position ........................................................	188
Adjusting the rear frame position .....................................	189
Checking engine oil level.................................................	193
Changing engine oil and filter, cleaning oil screen x........	194
Draining engine oil, cleaning oil screens x......................	194
Removing oil filter x.....................................................	197

CONTENTS	6
Fitting oil filter x..........................................................	199
Filling up with engine oil x............................................	199
Topping up engine oil .....................................................	201
TROUBLESHOOTING..........................................................	203
IMMOBILIZER FLASH CODE ...............................................	206
ENGINE CONTROL FLASH CODE.........................................	208
CLEANING.........................................................................	215
Cleaning motorcycle .......................................................	215
CONSERVATION FOR WINTER OPERATION .........................	217
Conservation for winter operation .....................................	217
STORAGE ..........................................................................	218
Storage..........................................................................	218
Putting into operation after storage ..................................	219
TECHNICAL DATA - ENGINE...............................................	220
Capacityengine oil ........................................................	221
Capacity - coolant...........................................................	221
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	222
TECHNICAL DATA - CHASSIS .............................................	225
Lighting equipment ........................................................	226
Capacity - fuel................................................................	227
TECHNICAL DATA - FORK...................................................	228
TECHNICAL DATA - SHOCK ABSORBER ..............................	229
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........	231
SUBSTANCES....................................................................	234
AUXILIARY SUBSTANCES...................................................	237
STANDARDS......................................................................	239
INDEX ...............................................................................	240

MEANS OF REPRESENTATION

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

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 service schedule 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 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

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 repair and 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

Overview2.1	of labels

700380-01

IMPORTANT NOTES

1Information on putting into operation

2Type label for Canada

3Type label for the USA

4Emission control information

5Noise emission information

6Chain tension information

7Information on suspension setting

8Fuel evaporative system information

Information on putting into operation

700210-01

IMPORTANT NOTES

700381-01

Type label for Canada

700382-01

Type label for the USA

IMPORTANT NOTES

700383-01

Emission control information

700384-01

Noise emission information

IMPORTANT NOTES

700385-01

Chain tension information

Information on suspension setting

700386-01

	IMPORTANT NOTES	15
		Fuel evaporative system information
		Fuel evaporative system information

700387-01

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 they are missing, you or others may not recognize dangers and may therefore be injured.

IMPORTANT NOTES

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Note

Danger of serious damage to machine or material.

Warning

Risk 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.

Reporting safety defects

If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.

If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236; or visit www.nhtsa.dot.gov; or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.

IMPORTANT NOTES

Noise emission warranty

KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to:

KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Telephone: (440) 985–3553

www.ktmusa.com

KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Canada Telephone: (450) 441–4451 x 39

www.ktmcanada.com

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or

2The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.

2Removal or puncturing of any part of the intake system.

3Lack of proper maintenance.

4Replacement of any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

IMPORTANT NOTES

Operating noise warning

This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

Consumer rights

Warranty claims should be directed to a KTM workshop. If you wish to make a complaint, please contact:

KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA

Telephone: (440) 985–3553

www.ktmusa.com

KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Canada

Telephone: (450) 441–4451 x 39

www.ktmcanada.com

Your rights may vary depending on national and regional laws.

	VIEW OF VEHICLE	20

	3View.1 of vehicle, front left side

700243-10

	VIEW OF VEHICLE		21

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	22

	View3.2 of vehicle, rear right side

700242-10

VIEW OF VEHICLE

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

4Chassis.1 number/type label

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

Type label for the USA is on the frame above the chassis number.

The type label for Canada is fixed to the frame on the left behind the steering head.

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

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

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

CONTROLS

Clutch5.1 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 hand brake lever is fitted on the right side of the handlebar.

The hand brake lever operates the front brake.

700228-01

CONTROLS

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

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