KTM 1190 RC8 USA User Manual

OWNER'S MANUAL 2008

1190 RC8 USA

ART. NO. 3211307en

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 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 2

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
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

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 4

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 5

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

Capacity- engine 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 7

1MEANSOFREPRESENTATION

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

Brand™ Identifies a trademark.

Identifies a protected name.

IMPORTANT NOTES 8

2IMPORTANTNOTES

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 9

You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following 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

2.1Overview of labels

700380-01

IMPORTANT NOTES 11

1 Information on putting into operation
2 Type label for Canada
3 Type label for the USA
4 Emission control information
5 Noise emission information
6 Chain tension information
7 Information on suspension setting
8 Fuel evaporative system information

Information on putting into operation

700210-01

IMPORTANT NOTES 12

700381-01

Type label for Canada

700382-01

Type label for the USA

IMPORTANT NOTES 13

700383-01

Emission control information

700384-01

Noise emission information

IMPORTANT NOTES 14

700385-01

Chain tension information

Information on suspension setting

700386-01

IMPORTANT NOTES 15

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 16

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 17

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: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Canada
Telephone: [phone] 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:

1 The 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

2 The 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:

1 Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacement 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 18

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: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Canada
Telephone: [phone] x 39
www.ktmcanada.com
Your rights may vary depending on national and regional laws.

19

VIEW OF VEHICLE 20

3VIEWOFVEHICLE

3.1

View 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

3.2View of vehicle, rear right side

700242-10

VIEW OF VEHICLE 23

1 Passenger seat
2 Supporting strap
3 Rear mirror
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Hand brake lever
7 Chassis number, type label
8 Rear brake caliper
9 Foot brake pedal
10 Engine number
11 Brake calipers, front

LOCATION OF SERIAL NUMBERS 24

4LOCATIONOFSERIALNUMBERS

4.1

Chassis 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

4.2Key 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 25

4.3Engine number

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

700223-01

4.4Fork part number

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

700224-01

LOCATION OF SERIAL NUMBERS 26

4.5Shock 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

4.6Steering damper part number

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

700226-01

CONTROLS 27

5CONTROLS

5.1Clutch lever

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulic and self-adjusting.

700227-01

5.2Hand 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 28

5.3Light 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

5.4Headlight 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