KTM 1190 RC8 EU 2008 Manual

SETUP INSTRUCTIONS 2008
1190 RC8 EU
1190 RC8 AUS/UK
1190 RC8 FR
1190 RC8 JP
ART. NO. 3211398en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-
tions, 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 may contain special
equipment that does not belong to the regular scope of delivery.
© 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)
Within the meaning of 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

MEANS OF REPRESENTATION 2
1MEANS OF REPRESENTAT ION
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).
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.

SET‑UP 3
2SET‑UP
2.1Unpacking and setting up the vehicle
–Remove the cardboard packing material.
700354-01
–Remove the adhesive tape at the top of the motorcycle.
700355-01
–Roll down the plastic sheeting on the sides.
Info
To avoid damaging the motorcycle while unpacking it, leave the remaining
plastic sheeting on the motorcycle until you have finished.
–Remove the separate enclosure from the seat.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
–Check the vehicle for transport damage.
700356-01
–Remove plastic from the handlebar stubs.
–Remove screw with distance sleeve from both handlebar stubs.
–Adjust the handlebar height. ( p. 5)
Info
Mount the handlebar stubs in the low position.
700357-01
–Remove the side screws on the left holder.
–Remove the top screws on the left holder.
–Loosen the holder from the base frame in an upward direction.
700358-01
–Remove the side screws on the right holder.
–Remove the top screws on the right holder.
–Leave the holder on the base frame.
Info
The motorcycle is leaning toward the right and is resting against the holder
on the base frame.

SET‑UP 4
700359-01
–Remove nut on the left holder.
–Remove the left holder.
Info
The threaded stud is no longer fixed on the left side.
700360-01
–With the assistance of another person, stand the motorcycle upright.
–Remove the right holder with the nut and threaded stud toward the side.
–Push the motorcycle off of the pallet.
–Remove the remaining plastic sheeting.
700217-01
–Mount the reflector.
700365-01
–Remove the seat. ( p. 6)
–Activate lever .
–Remove locking caps .
–Fit the passenger seat. ( p. 6)
–Recharge the battery. ( p. 6)
–Stow away the tool set under the seat.
–Fit the seat. ( p. 6)
700366-01
–Remove screws  and bushings on the left and right sides of the vehicle.
–Mount the passenger footrests on the left and right sides of the vehicle using the
screws from the separate enclosure.
Guideline
Screw, rear footrest bracket M8 25 Nm
(18.4 lbf ft)
–Fill up with fuel. ( p. 7)
–Set kilometers/miles SET KM/MILES. ( p. 8)
–Set the clock with SET CLOCK. ( p. 8)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 5
3WORK
3.1Adjusting the handlebar height
Info
The handlebar stub position must be identical on the left and right of the vehicle.
700318-01
Adjusting the high position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
–Remove screw .
700319-01
–Remove distance sleeve .
–All cables routed under the upper triple clamp must now be routed under the
handlebar stub.
–Push the handlebar stub carefully up to the upper triple clamp.
–Position the distance sleeve above the triple clamp.
–Mount and tighten the screw.
Guideline
Remaining chassis screws M5 5 Nm (3.7 lbf ft)
700320-01
–Tighten the screw.
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
–Repeat the adjustments on the other handlebar stub.
–Move the handlebar to and fro over the entire steering range.
» If the cables restrict the freedom of movement of the steering:
–Correct the cable routing.
700320-11
Adjusting the low position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork lacquer
when moving the handlebar stub.
700319-11
–Remove screw with distance sleeve .
–Carefully shift the handlebar stub by the length of the distance sleeve.
Guideline
Long distance sleeve 15 mm (0.59 in)
–Lay all cables between the upper triple clamp and the handlebar stub.
–Position the distance sleeves.
–Mount and tighten the screw.
Guideline
Remaining chassis screws M5 5 Nm (3.7 lbf ft)

WORK 6
700362-01
–Tighten the screw.
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
–Repeat the adjustments on the other handlebar stub.
–Move the handlebar to and fro over the entire steering range.
» If the cables restrict the freedom of movement of the steering:
–Correct the cable routing.
3.2Removing the seat
700245-01
–Insert the ignition key in the seat lock and turn it anticlockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
3.3Fitting the passenger seat
700275-01
–Position the passenger seat in the space provided.
–Press down the passenger seat until it clicks into place.
–Finally, check that the passenger seat is correctly mounted.
3.4Fitting the seat
700269-01
–Position the recesses of the seat to the lugs on the frame, lower the rear end and
simultaneously push it forward.
–Lock the seat by turning the ignition key in the seat lock.
–Remove the ignition key from the seat lock.
–Finally, check that the seat is correctly mounted.
3.5Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard Components and battery acid are a danger to the environment.
–Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

WORK 7
Warning
Environmental hazard Problem materials cause environmental damage.
–Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery becomes discharged from starting, it must be recharged immediately.
If the battery rests for an extended time in a discharged state, it becomes over-discharged and sulfated, which will result in its
destruction.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power-consuming components and switch off the engine.
–Remove the seat. ( p. 6)
–Disconnect the negative (minus) cable of the battery to prevent damage to the vehi-
cle's electronics.
100151-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid .
Charge the battery according to the instructions on the battery casing.
–After charging the battery, switch off the battery charger. Reconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
3 months
–Fit the seat. ( p. 6)
3.6Refueling
Danger
Fire hazard Fuel can easily catch fire.
–Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.

WORK 8
Info
This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded
fuel only.
700321-01
–Switch off engine.
–Open the filler cap.
–Fill the fuel tank with fuel up to the lower edge of the fuel filler.
Total fuel tank
capacity, approx.
16.5 l
(4.36 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 11)
–Close the filler cap.
3.7Setting kilometers/miles SET KM/MILES
Info
Making a country-specific setting.
Condition
The ignition is on.
The motorcycle is standing.
400464-01
–Press the button and the button for 3 - 5 seconds.
–Press the button three times until the symbol is on UNITS in the info display.
–Press the button or the button briefly and repeatedly until the symbol is
on SET KM/MILES in the info display.
–Press the MODE button briefly.
The selected unit appears on the left of the display.
–Select the unit with the button or the button .
–Press the MODE button briefly.
The settings are stored and the display changes to the UNITS menu.
–Press the button briefly and repeatedly until the symbol is on BACK... in the
info display.
–Press the MODE button briefly.
–Press the button briefly and repeatedly until the symbol is on EXIT SETUP in
the info display.
–Press the MODE button briefly.
3.8Setting the clock with SET CLOCK
Condition
The ignition is on.
The motorcycle is standing.
400455-01
–Press the button and the button for 3 - 5 seconds.
–Press the button once until the symbol is on SET CLOCK in the info display.
–Press the MODE button briefly.
The hour is shown.
–Set the hour with the button or the button .
–Press the MODE button briefly.
The minutes are shown.
–Set the minutes with the button or the button .
–Press the MODE button briefly.
The settings are stored and the display changes to the SET‑UP menu.
–Press the button briefly and repeatedly until the symbol is on EXIT SETUP in
the info display.
–Press the MODE button briefly.

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 9
4TECHNICAL DATA - CHASSIS T IGHTENING TORQUES
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite®243™
Screw, brake fluid reservoir of rear
brake
M5 5 Nm (3.7 lbf ft) Loctite®243™
Screw, brake line holder M5 5 Nm (3.7 lbf ft) –
Screw, chain sliding piece M5 5 Nm (3.7 lbf ft) –
Screw, chain guard M5 5 Nm (3.7 lbf ft) –
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, fuel tank guard M5x17 3 Nm (2.2 lbf ft) –
Screw, steering damper fixing bracket M5 5 Nm (3.7 lbf ft) Loctite®243™
Remaining chassis screws M5 5 Nm (3.7 lbf ft) –
Remaining chassis nuts M6 15 Nm (11.1 lbf ft) –
Screw, exhaust heat shield M6 15 Nm (11.1 lbf ft) –
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft) –
Screw, foot brake pedal M6 15 Nm (11.1 lbf ft) Loctite®243™
Screw, footbrake pedal stub M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, footbrake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft) –
Screw, shift lever stub M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift rod M6 12 Nm (8.9 lbf ft) Loctite®243™
Screw, shift shaft deflector on chain
securing guide
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift shaft deflector on shift
shaft
M6 18 Nm (13.3 lbf ft) Loctite®243™
Remaining chassis screws M6 10 Nm (7.4 lbf ft) –
Remaining chassis nuts M8 30 Nm (22.1 lbf ft) –
Nut, forked bracket on footbrake pedal M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw of rear brake caliper M8 22 Nm (16.2 lbf ft) Loctite®243™
Screw, spring holder on side stand
bracket
M8 15 Nm (11.1 lbf ft) Loctite®243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, handlebar stub M8 20 Nm (14.8 lbf ft) –
Screw, steering damper fixing bracket M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, steering damper clamp on con-
sole
M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, work stand adapter M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, subframe M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, shift lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, ignition lock (ratchet screw) M8 Loctite®243™
Remaining chassis screws M8 25 Nm (18.4 lbf ft) –
Remaining chassis nuts M10 50 Nm (36.9 lbf ft) –
Rear sprocket bolt M10x1.25 50 Nm (36.9 lbf ft) Loctite®243™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Screw, shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, engine bearer M10 45 Nm (33.2 lbf ft) –

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 10
Screw, sidestand M10 35 Nm (25.8 lbf ft) Loctite®243™
Screw, connecting lever, shock
absorber deflector
M10 45 Nm (33.2 lbf ft) Loctite®243™
Remaining chassis screws M10 45 Nm (33.2 lbf ft) –
Nut of bell crank on frame M14x1.5 100 Nm (73.8 lbf ft) –
Lambda probe M18x1.5 45 Nm (33.2 lbf ft) –
Nut, swingarm pivot M19x1.5 130 Nm (95.9 lbf ft) Thread greased
Screw, seat lock M22x1.5 8 Nm (5.9 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased
Screw, front wheel spindle M25x1.5 45 Nm (33.2 lbf ft) –
Screw, steering head M25x1.5 18 Nm (13.3 lbf ft) –

SUBSTANCES 11
5SUBSTANCES
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
–DIN EN 228 (ROZ 95 / RON 95 / PON 91)

*3211398en*
3211398en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
16.05.2008 Photo Mitterbauer