KTM 1190 RC8 R E 2015 User manual

SETUP INSTRUCTIONS 2015
1190 RC8 R EU/GB
1190 RC8 R FR
1190 RC8 R JP
1190 RC8 R US
Art. no. 3213319en

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 GmbH specifically 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, misprints, and other errors. The models portrayed partly contain special equip-
ment that does not belong to the regular scope of supply.
© 2015 KTM Sportmotorcycle GmbH, 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 GmbH
5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
Preparatory work
–Remove the box.
201904-10
Main work
–Remove the adhesive tape in the upper area of the motorcycle.
201905-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking, leave the other films
on the vehicle until you have finished work on the vehicle.
–Remove the separate enclosure from the seat.
–Unpack the separate enclosure and check its contents on the basis of the scope of
supply.
–Check the vehicle for transport damage.
201906-10
–Remove screw with the distance sleeve from both handlebar stubs.
–Adjust the handlebar height/position. ( p. 5)
Info
Mount the handlebar stubs in the low position.
201907-10
–Remove screws of the retaining bracket on both sides.
Guideline
An assistant holds the motorcycle.
–Remove nut .
–Remove the retaining bracket and threaded rod on both sides.
–Push the motorcycle off of the pallet.
201901-10
–Mount the reflector.

2 SETUP 4
201908-10
–Remove the seat. ( p. 7)
–Activate lever .
–Remove locking caps .
–Mount the passenger seat. ( p. 7)
201909-10
–Recharge the battery. ( p. 8)
–Pull the fuse box out of the holder.
–Plug in connector .
–Mount the fuse box.
(1190 RC8 R EU/GB/FR/JP)
–Store the tool set below the seat.
–Fit the seat. ( p. 7)
201910-10
–Remove screws and the bushings on both sides.
–Mount the passenger footrests on both sides with the screws from the separate
enclosure.
Guideline
Screw, rear footrest bracket M8 25 Nm
(18.4 lbf ft)
–Remove the remaining films.
–Fill up with fuel. ( p. 9)
–Set the kilometers/miles SET KM/MILES. ( p. 10)
–Set the clock with SET CLOCK. ( p. 11)
–Print out the current PDI form found on the KTM Dealer.net and perform the pre-
delivery inspection.
–Perform a fault memory query.

3 WORK 5
3.1 Adjusting the handlebar height/position
Info
The handlebar stub position must be identical on the left and right of the vehicle.
100756-11
Adjusting the high position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork paint when
moving the handlebar stub.
–Remove screw .
100757-10
–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. Watch out for
the handlebar position difference.
Guideline
Handlebar position difference 6.5°
–Position the distance sleeve above the triple clamp.
–Mount and tighten screw.
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
100759-01
–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.
» If a component restricts the freedom of movement of the steering or comes
into contact with the trim:
–Establish freedom of movement and reposition the component.
100759-10
Adjusting the low position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork paint when
moving the handlebar stub.
100760-10
–Remove screw with distance sleeve .
–Carefully shift the handlebar stub by the length of the distance sleeve. Watch
out for the handlebar position difference.
Guideline
Length, distance sleeve 15 mm (0.59 in)
Handlebar position difference 6.5°
–Lay all cables between the upper triple clamp and the handlebar stub.
–Position the distance sleeve.

3 WORK 6
–Mount and tighten screw.
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
100761-01
–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.
» If a component restricts the freedom of movement of the steering or comes
into contact with the trim:
–Establish freedom of movement and reposition the component.
600986-11
Adjusting the narrow position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork paint when
moving the handlebar stub.
–Remove screw with distance sleeve.
–Carefully turn the handlebar stub toward the fuel tank.
Guideline
Handlebar position difference 6.5°
600986-10
–Position the distance sleeve.
–Mount and tighten screw .
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
–Tighten screw .
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
–Repeat the adjustments on the other handlebar stub.
–Carefully move the handlebar to and fro over the entire steering range.
» If a component restricts the freedom of movement of the steering or comes
into contact with the trim:
–Establish freedom of movement and reposition the component.
600986-10
Adjusting the wide position of the handlebar stubs:
–Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork paint when
moving the handlebar stub.
–Remove screw with distance sleeve.
–Carefully turn the handlebar stub away from the fuel tank.
Guideline
Handlebar position difference 6.5°

3 WORK 7
600986-11
–Position the distance sleeve.
–Mount and tighten screw .
Guideline
Remaining frame bolts M5 5 Nm (3.7 lbf ft)
–Tighten screw .
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
–Repeat the adjustments on the other handlebar stub.
–Carefully move the handlebar to and fro over the entire steering range.
» If a component restricts the freedom of movement of the steering or comes
into contact with the trim:
–Establish freedom of movement and reposition the component.
3.2 Removing the seat
B01308-11
–Insert the ignition key in the seat lock and turn it clockwise.
–Raise the rear of the seat, push it towards the rear, and remove it upwards.
3.3 Mounting the passenger seat
B01326-01
Warning
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
–After mounting the passenger seat, check that it is locked correctly by
pulling up.
–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.
3.4 Fitting the seat
M00975-01
–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 WORK 8
3.5 Recharging 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 sparks and open flames away from the battery. Only charge 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 The battery contains elements that are harmful to the environment.
–Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 7)
–Disconnect the negative cable of the battery to avoid damage to the onboard elec-
tronics.
M00702-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the rest potential and start potential of
the battery, and to test the alternator. With this device, you cannot overcharge the
battery.
Info
Never remove lid .
Charge the battery to a maximum of 10% of the capacity specified on bat-
tery housing .
–Switch off the battery charger after charging and disconnect from 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
–Connect the negative cable with the battery.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
Finishing work
–Fit the seat. ( p. 7)

3 WORK 9
–Set the clock with SET CLOCK. ( p. 11)
3.6 Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel 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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–Only refuel with clean fuel that meets the specified standards.
Note
Material damage Incorrect mapping damages the engine.
–Adjust the mapping of the engine electronics for the fuel quality currently in use.
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.
B01312-10
–Switch off the engine.
–Open the filler cap. ( p. 9)
–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. 14)
Super unleaded (ROZ 98 / RON 98 /
PON 94) ( p. 14)
–Close the filler cap. ( p. 10)
–Adjust the mapping of the engine electronics. ( p. 11)
3.7 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel 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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with
fuel. Store fuel properly in a suitable canister and keep away from children.
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.

3 WORK 10
B01306-10
–Lift the cover of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
3.8 Closing the filler cap
B01307-01
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–After closing the filler cap, ensure that it is locked properly. Change
clothing that has been contaminated with fuel. Immediately clean con-
taminated areas on the skin with soap and water.
–Close the filler cap. Push down the filler cap slightly until the lock closes.
–Remove the ignition key and close the cover.
3.9 Setting the kilometers/miles SET KM/MILES
Info
Making a country-specific setting.
Condition
The ignition is on.
The motorcycle is stationary.
401154-01
–Press the button and the button for 3 - 5 seconds.
–Press the button three times until the symbol shows UNITS in the info display.
–Press the MODE button briefly.
–Press the MODE button briefly.
The selected unit appears on the left in 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 shows BACK... in the
info display.
–Press the MODE button briefly.
–Press the button briefly and repeatedly until the symbol shows EXIT SETUP in
the info display.
–Press the MODE button briefly.

3 WORK 11
3.10 Setting the clock with SET CLOCK
Condition
The ignition is on.
The motorcycle is stationary.
400455-01
–Press the button and the button for 3 - 5 seconds.
–Press the button once until the symbol shows 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 shows EXIT SETUP in
the info display.
–Press the MODE button briefly.
3.11 Adjusting the mapping of the engine electronics ENGINE MAP
Note
Material damage Incorrect mapping damages the engine.
–Adjust the mapping of the engine electronics for the fuel quality currently in use.
Condition
The ignition is on.
The motorcycle is stationary.
401134-01
Condition
ROAD mode
–Press the MODE button briefly and repeatedly until ENGINE MAP appears in the
info display.
–Press the MODE button for 3 - 5 seconds.
–Select the mapping with the button or the button .
–Press the MODE button for 3 - 5 seconds.
The setting is stored.
401148-01
Condition
RACE mode
–Press the MODE button briefly and repeatedly until ENGINE MAP appears in the
info display.
–Press the MODE button for 3 - 5 seconds.
–Select the mapping with the button or the button .
–Press the MODE button for 3 - 5 seconds.
The setting is stored.

4 TECHNICAL DATA 12
4.1 chassis tightening torques
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite®243™
Remaining frame bolts M5 5 Nm (3.7 lbf ft) –
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 guard M5 5 Nm (3.7 lbf ft) –
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft) –
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, fuel tank guard M5x12 3 Nm (2.2 lbf ft) –
Screw, painted trim parts M5 3.5 Nm (2.58 lbf ft) –
Screw, steering damper fixing bracket M5 5 Nm (3.7 lbf ft) Loctite®243™
Bolt, foot brake lever stub M6 10 Nm (7.4 lbf ft) Loctite®243™
Remaining chassis nuts M6 10 Nm (7.4 lbf ft) –
Remaining chassis screws M6 10 Nm (7.4 lbf ft) –
Screw for wheel speed sensor bracket M6 3 Nm (2.2 lbf ft) Loctite®243™
Screw, exhaust clamp M6 8 Nm (5.9 lbf ft) –
Screw, exhaust heat shield M6 15 Nm (11.1 lbf ft) –
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, foot brake lever M6 15 Nm (11.1 lbf ft) Loctite®243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft) –
Screw, mirror bracket 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 7 Nm (5.2 lbf ft) Loctite®243™
Screw, shift shaft deflector on shift
shaft
M6 18 Nm (13.3 lbf ft) Loctite®243™
Fork end pinch bolts M8 15 Nm (11.1 lbf ft) –
Nut, forked bracket on foot brake lever M8 30 Nm (22.1 lbf ft) Loctite®243™
Remaining chassis nuts M8 25 Nm (18.4 lbf ft) –
Remaining chassis screws M8 25 Nm (18.4 lbf ft) –
Screw for lifting gear support, rear M8 18 Nm (13.3 lbf ft) –
Screw of rear brake caliper M8 22 Nm (16.2 lbf ft) Loctite®243™
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, clamp, eccentric shaft of
deflector
M8 18 Nm (13.3 lbf ft) –
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar stub M8 20 Nm (14.8 lbf ft) –
Screw, ignition lock M8 16 Nm (11.8 lbf ft) Loctite®243™
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, rear footrest bracket (footrest
bracket not mounted)
M8x25 15 Nm (11.1 lbf ft) –
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, spring holder on side stand
bracket
M8 15 Nm (11.1 lbf ft) Loctite®243™
Screw, steering damper clamp on con-
sole
M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, steering damper fixing bracket
on triple clamp
M8 10 Nm (7.4 lbf ft) Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft) –

4 TECHNICAL DATA 13
Screw, subframe M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Remaining chassis nuts M10 45 Nm (33.2 lbf ft) –
Remaining chassis screws M10 45 Nm (33.2 lbf ft) –
Screw, connecting lever, shock
absorber deflector
M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, engine bearer M10 45 Nm (33.2 lbf ft) –
Screw, shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite®243™
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™
Nut of bell crank on frame M14x1.5 100 Nm (73.8 lbf ft) –
Lambda sensor 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) –
Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased
Screw, steering head M25x1.5 18 Nm (13.3 lbf ft) –

5 SUBSTANCES 14
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded (ROZ 98 / RON 98 / PON 94)
Standard/classification
–DIN EN 228 (ROZ 98 / RON 98 / PON 94)

*3213319en*
3213319en
03/2015
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM