KTM 1190 RC8 User manual

OWNER'S MANUAL 2009
1190 RC8 EU/UK
1190 RC8 AUS
1190 RC8 FR
1190 RC8 JP
ART. NO. 3211373en

DEAR KTM CUSTOMER 1
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. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 16)
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 misprints 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
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side............................................ 12
View of vehicle, rear right side ........................................... 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number/type label................................................. 16
Key number ..................................................................... 16
Engine number................................................................. 17
Fork part number.............................................................. 17
Shock absorber part number.............................................. 18
Steering damper part number ............................................ 18
OPERATING ELEMENTS....................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Light switch ..................................................................... 20
Headlight flasher switch.................................................... 20
Flasher switch.................................................................. 21
Horn button ..................................................................... 21
Ignition/steering lock ........................................................ 22
Emergency OFF switch...................................................... 22
Electric starter button ....................................................... 23
Combination instrument - overview..................................... 24
Combination instrument - function buttons on handlebar ..... 25
Combination instrument - activation and test ...................... 26
Display ............................................................................ 27
Info display...................................................................... 28
Indicator lamps ................................................................ 29
Notes/warnings on the combination instrument.................... 30
Odometer menu ODO/Trip 1 .............................................. 33
Odometer menu ODO/Trip 2 .............................................. 34
FUELDISTANCE menu...................................................... 35
FUELRANGE menu........................................................... 36
DISTANCE TO Next Service menu...................................... 37
LAPSTOGO menu ............................................................. 38
TOPSPEED menu ............................................................. 39
LAP/BESTLAP/LastLap menu............................................. 40
LAP/BESTLAP/TopSpeed menu.......................................... 41
Total distance menu in Race mode RACEODO..................... 42
SET‑UP menu .................................................................. 43
CHANGE MODE menu ...................................................... 44
SET CLOCK menu ............................................................ 45
SETTINGS menu .............................................................. 46
SHIFT RPMS menu .......................................................... 47
LAP menu, LAP BLANK T button ....................................... 48
SET NUM LAPS menu ...................................................... 49
TRIP F RESET menu ........................................................ 50
UNITS menu.................................................................... 51
SET KM/MILES menu ....................................................... 52
SET °C/°F menu ............................................................... 53
OPTIONS menu................................................................ 54
TPMS menu..................................................................... 55
OUTERTEMP menu .......................................................... 56
Displaying lap times ......................................................... 61
Displaying maximum speed ............................................... 62
Setting ROAD or RACE mode............................................. 63
Setting the clock with SET CLOCK ..................................... 63
Adjusting shift speed RPM1/2 ........................................... 64

CONTENTS 4
Setting the blank time of the LAP button LAP BLANK T....... 65
Setting the number of laps SET NUM LAPS........................ 67
Setting the fuel reserve display TRIPF RESET ..................... 68
Setting the kilometers/miles SET KM/MILES....................... 69
Setting the temperature unit SET °C/°F .............................. 70
Switching the external temperature display on/off ................ 70
Opening the filler cap ....................................................... 72
Closing the filler cap......................................................... 73
Supporting strap............................................................... 73
Seat lock ......................................................................... 74
Tool set ........................................................................... 74
Helmet lock ..................................................................... 75
Passenger footrests........................................................... 75
Shift lever........................................................................ 76
Foot brake pedal .............................................................. 77
Side stand ....................................................................... 77
TIPS ON PUTTING INTO OPERATION .................................... 78
Advice on first use............................................................ 78
Running the engine in....................................................... 79
Loading the vehicle .......................................................... 80
RIDING INSTRUCTIONS ....................................................... 82
Checks to be made before putting into operation ................. 82
Starting ........................................................................... 83
Starting up ...................................................................... 84
Shifting, riding................................................................. 85
Braking ........................................................................... 88
Stopping, parking ............................................................. 89
Refueling......................................................................... 90
SERVICE SCHEDULE............................................................ 92
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. ......................................................... 92
Important service tasks to be carried out by an authorized
KTM-RC8 workshop. (as additional job) .............................. 95
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 96
Jacking up motorcycle front............................................... 96
Taking front of motorcycle off work stand............................ 96
Jacking up motorcycle rear ................................................ 97
Taking rear of motorcycle off work stand ............................. 97
Fork/shock absorber.......................................................... 98
Adjusting the compression damping of the fork ................... 98
Adjusting the rebound damping of the fork.......................... 99
Adjusting the spring preload of the fork ............................ 100
Bleeding fork legs........................................................... 101
Compression damping of the shock absorber ..................... 102
Adjusting the low-speed compression damping of the
shock absorber ............................................................... 102
Adjusting the high-speed compression damping of the
shock absorber ............................................................... 103
Adjusting the rebound damping of the shock absorber........ 104
Adjusting the spring preload of the shock absorber x....... 105
Steering damper............................................................. 107
Adjusting the steering damper ......................................... 107
Vehicle level .................................................................. 109
Adjusting front vehicle level x........................................ 110
Adjusting the vehicle level at the rear ............................... 112
Footrest position............................................................. 114
Adjusting footrest position............................................... 114
Adjusting shift lever stub................................................. 116

CONTENTS 5
Adjusting shift lever........................................................ 116
Adjusting the footbrake pedal stub ................................... 120
Adjusting the footbrake pedal .......................................... 121
Checking for chain dirt.................................................... 121
Cleaning the chain.......................................................... 122
Checking the chain tension ............................................. 123
Adjusting the chain tension ............................................. 124
Checking rear sprocket / engine sprocket for wear .............. 126
Checking chain wear....................................................... 127
Checking chain sliding guard........................................... 128
Checking the front brake discs......................................... 128
Checking the rear brake disc............................................ 129
Adjusting the basic position of the handbrake lever............ 130
Checking brake fluid level of front brake........................... 130
Topping up brake fluid of front brake x........................... 131
Brake linings.................................................................. 132
Checking the front brake linings....................................... 133
Checking rear brake fluid level......................................... 134
Topping up rear brake fluid x........................................ 134
Checking the rear brake linings........................................ 136
Removing the front wheel x........................................... 136
Fitting front wheel x..................................................... 138
Removing rear wheel x.................................................. 139
Installing the rear wheel x............................................. 140
Checking rear hub shock absorbers x............................. 143
Checking the tire condition.............................................. 143
Checking tire air pressure................................................ 145
Removing the seat.......................................................... 146
Fitting the seat............................................................... 146
Removing the passenger seat........................................... 147
Mounting the passenger seat ........................................... 147
Mounting the helmet lock on the vehicle........................... 148
Removing the battery x................................................. 148
Installing the battery x.................................................. 150
Recharging the battery x............................................... 152
Changing the main fuse .................................................. 154
Changing the fuses of individual power consumers............. 156
Changing the low beam bulb............................................ 158
Changing the high beam lamp ......................................... 161
Changing the parking light bulb ....................................... 165
Checking headlight adjustment........................................ 168
Adjusting headlamp range ............................................... 168
Activating/deactivating ignition key .................................. 169
Cooling system ............................................................... 172
Checking the coolant level............................................... 173
Filling the cooling system compensating tank.................... 174
Adjusting basic position of clutch lever............................. 176
Checking fluid level of hydraulic clutch ............................ 176
Correcting fluid level of hydraulic clutch........................... 177
Adjusting the gas Bowden cable x.................................. 178
Handlebar height............................................................ 178
Adjusting the handlebar height ........................................ 179
Rear frame position ........................................................ 181
Adjusting the rear frame position ..................................... 182
Checking engine oil level................................................. 186
Changing engine oil and filter, cleaning oil screen x........ 187
Draining engine oil, cleaning oil screens x...................... 187
Removing the oil filter x................................................ 190

CONTENTS 6
Installing the oil filter x................................................ 192
Filling up with engine oil x............................................ 192
Adding engine oil ........................................................... 194
TROUBLESHOOTING.......................................................... 196
IMMOBILIZER FLASH CODE ............................................... 199
ENGINE CONTROL FLASH CODE......................................... 201
CLEANING......................................................................... 206
Cleaning motorcycle ....................................................... 206
CONSERVATION FOR WINTER OPERATION ......................... 208
Conservation for winter operation ..................................... 208
STORAGE .......................................................................... 209
Storage.......................................................................... 209
Putting into operation after storage .................................. 210
TECHNICAL DATA - ENGINE............................................... 211
Capacity- engine oil ........................................................ 212
Capacity - coolant........................................................... 212
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 213
TECHNICAL DATA - CHASSIS ............................................. 216
Lighting equipment ........................................................ 217
Capacity - fuel................................................................ 218
TECHNICAL DATA - FORK................................................... 219
TECHNICAL DATA - SHOCK ABSORBER .............................. 220
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 222
SUBSTANCES.................................................................... 225
AUXILIARY SUBSTANCES................................................... 229
STANDARDS...................................................................... 231
INDEX ............................................................................... 232

MEANS OF REPRESENTATION 7
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 opti-
mally 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 8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for use
on dirt roads.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
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 consid-
erably 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 ser-
vice 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 The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
–Switch off the engine and remove the ignition key.
–Secure the motorcycle against falling over or running away using straps or other suitable devices.
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 con-

IMPORTANT NOTES 10
flicts. To ensure the future of motorcycle sport, make sure you use the motorcycle legally, demonstrate a consciousness for the environ-
ment, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–Be sure to read this owner's manual carefully and completely before taking your first ride. 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. This owner's manual also contains important information about servicing the motorcycle.

IMPORTANT NOTES 11
–The owner's manual is an important component of the motorcycle and should be passed on to the new owner if the bike is sold.

VIEW OF VEHICLE 12
3.1View of vehicle, front left side
700243-10

VIEW OF VEHICLE 13
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 14
3.2View of vehicle, rear right side
700242-10

VIEW OF VEHICLE 15
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 16
4.1Chassis number/type label
700231-01
The chassis number is stamped on the frame behind the steering head on the right.
The type label is on the frame above the chassis number.
4.2Key number
700222-01
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.

LOCATION OF SERIAL NUMBERS 17
4.3Engine number
700223-01
The engine number is stamped on the right side of the engine.
4.4Fork part number
700224-01
The fork part number is stamped on the inner side of the fork stub.

LOCATION OF SERIAL NUMBERS 18
4.5Shock absorber part number
700225-01
The shock absorber part number is stamped on the upper part of the shock absorber
above the adjusting ring towards the rear.
4.6Steering damper part number
700226-01
The steering damper part number is stamped on the top of the steering damper.