KTM 1190 RC8 R EU/UK 2009 Owner's manual

OWNER'S MANUAL 2013

1190 RC8 R USA

Art. no. 3211962en

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 a lot of enjoyment in riding this vehicle.

Please enter the serial numbers of your vehicle below.

Vehicle identification number/type label ( p. 28) Dealer's stamp

Engine number ( p. 29)

Key number ( p. 28)

The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in

design cannot be ruled out completely.

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 form part of the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

DEAR KTM CUSTOMER 2

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

TABLE OF CONTENTS 3

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ........................................ 8

1.1 Symbols used ...................................................... 8

1.2 Formats used....................................................... 8

2 SAFETY ADVICE.............................................................. 9

2.1 Use definition - intended use ................................ 9

2.2 Safety advice....................................................... 9

2.3 Degrees of risk and symbols................................ 10

2.4 Overview of labels .............................................. 12

2.5 Reporting safety defects ..................................... 17

2.6 Noise emission warranty ..................................... 18

2.7 Operating noise warning ..................................... 18

2.8 Consumer rights................................................. 18

2.9 Tampering warning............................................. 19

2.10 Safe operation ................................................... 19

2.11 Protective clothing ............................................. 20

2.12 Work rules......................................................... 20

2.13 Environment...................................................... 21

2.14 Owner's Manual ................................................. 21

3 IMPORTANT NOTES...................................................... 22

3.1 Guarantee, warranty ........................................... 22

3.2 Operating and auxiliary substances...................... 22

3.3 Spare parts, accessories ..................................... 22

3.4 Service ............................................................. 22

3.5 Figures ............................................................. 23

3.6 Customer service................................................ 23

4 VIEW OF VEHICLE ........................................................ 24

4.1 View of vehicle, front left (example) ..................... 24

4.2 View of vehicle, rear right (example) .................... 26

5 SERIAL NUMBERS ....................................................... 28

5.1 Vehicle identification number/type label............... 28

5.2 Key number....................................................... 28

5.3 Engine number .................................................. 29

5.4 Fork part number ............................................... 29

5.5 Shock absorber part number ............................... 30

5.6 Steering damper part number.............................. 30

6 CONTROLS................................................................... 31

6.1 Clutch lever....................................................... 31

6.2 Hand brake lever................................................ 31

6.3 Throttle grip ...................................................... 32

6.4 Horn button....................................................... 32

6.5 Light switch ...................................................... 33

6.6 Headlight flasher switch ..................................... 33

6.7 Turn signal switch.............................................. 34

6.8 Emergency OFF switch ....................................... 34

6.9 Electric starter button......................................... 35

6.10 Ignition/steering lock.......................................... 35

6.11 Combination instrument - overview ...................... 36

6.12 Combination instrument - function buttons on

handlebar.......................................................... 37

6.13 Combination instrument - activation and test........ 38

6.14 Display ............................................................. 39

6.15 Info display ....................................................... 40

6.16 Indicator lamps.................................................. 41

6.17 Immobilizer....................................................... 42

6.18 Notes/warnings on the combination instrument ..... 42

6.19 Overview of ROAD mode ..................................... 46

6.20 Distance menu 1, ODO/Trip 1/Time 1/Avs 1 ......... 47

TABLE OF CONTENTS 4

6.21 Distance menu 2, ODO/Trip 2/Time 2/Avs 2 ......... 48

6.22 Gear display menu, ODO/Trip 1/Gear.................... 49

6.23 Fuel and external temperature menu, FUEL.......... 51

6.24 Mapping menu, ENGINE MAP............................. 52

6.25 Next service menu, DISTANCE TO Next Service .... 53

6.26 Overview of RACE mode...................................... 54

6.27 Remaining laps menu, LAPSTOGO ...................... 55

6.28 Maximum lap speed menu, TOPSPEED................ 56

6.29 Gear display menu, LastLap/RaceTrip/Gear........... 58

6.30 Fuel and external temperature menu, FUEL.......... 59

6.31 Mapping menu, ENGINE MAP............................. 60

6.32 Lap times menu, LAP/BESTLAP/LapTime............. 61

6.33 Maximum speed menu, LAP/BESTLAP/

TopSpeed.......................................................... 62

6.34 Total distance in Race mode menu, RACEODO ..... 63

6.35 Overview of SET‑UP mode .................................. 64

6.36 SET‑UP menu.................................................... 66

6.37 Mode menu, CHANGE MODE.............................. 67

6.38 Time menu, SET CLOCK..................................... 68

6.39 SETTINGS menu................................................ 69

6.40 Shift warning lamp menu, SHIFT RPMS............... 70

6.41 LAP button blank time, LAP BLANK TIME

menu................................................................ 71

6.42 Number of laps menu, SET NUM LAPS................ 72

6.43 Fuel reserve display menu, TRIP F RESET............ 73

6.44 UNITS menu ..................................................... 75

6.45 Kilometers/miles menu, SET KM/MILES............... 76

6.46 Temperature display menu, SET °C/°F.................. 77

6.47 Fuel consumption menu (liters),

SET FUEL CONS ............................................... 78

6.48 Fuel consumption menu (gallons),

SET GAL US/UK ................................................ 79

6.49 Additional functions menu, OPTIONS .................. 80

6.50 Quick shifter menu, OPTION QKSHIFT ................ 81

6.51 External temperature display menu,

OPTION OUTTEMP ............................................ 82

6.52 Tire pressure monitor menu, OPTION TPMS ......... 83

6.53 Table of functions .............................................. 84

6.54 Table of conditions and menu activation .............. 88

6.55 Adjusting the mapping of the engine electronics

ENGINE MAP .................................................... 92

6.56 Displaying lap times........................................... 93

6.57 Displaying maximum speed................................. 93

6.58 Setting ROAD or RACE mode .............................. 94

6.59 Setting the clock with SET CLOCK....................... 95

6.60 Adjusting the shift speed RPM1/2 ....................... 95

6.61 Setting the blank time of the LAP button

LAP BLANK TIME.............................................. 97

6.62 Setting the number of laps SET NUM LAPS ......... 98

6.63 Setting the fuel reserve display TRIP F RESET...... 99

6.64 Setting the kilometers/miles SET KM/MILES ...... 100

6.65 Setting the temperature unit SET °C/°F.............. 101

6.66 Setting the unit of fuel consumption (liters)

SET FUEL CONS ............................................. 102

6.67 Unit of fuel consumption (gallons)

SET GAL US/UK .............................................. 103

6.68 Switching the external temperature display

on/off.............................................................. 104

6.69 Opening the filler cap....................................... 105

6.70 Closing the filler cap ........................................ 107

TABLE OF CONTENTS 5

6.71 Seat lock......................................................... 107

6.72 Tool set........................................................... 108

6.73 Supporting strap .............................................. 108

6.74 Passenger footrests .......................................... 109

6.75 Shift lever ....................................................... 109

6.76 Foot brake lever ............................................... 110

6.77 Side stand....................................................... 111

6.78 Helmet lock..................................................... 111

7 PREPARING FOR USE................................................. 112

7.1 Advice on first use ........................................... 112

7.2 Running the engine in ...................................... 113

7.3 Loading the vehicle.......................................... 114

8 RIDING INSTRUCTIONS.............................................. 116

8.1 Checks and maintenance measures when

preparing for use.............................................. 116

8.2 Starting........................................................... 117

8.3 Starting off...................................................... 118

8.4 Shifting, riding ................................................ 119

8.5 Braking........................................................... 122

8.6 Stopping, parking............................................. 123

8.7 Transport ........................................................ 124

8.8 Refueling ........................................................ 125

9 SERVICE SCHEDULE .................................................. 127

9.1 Service schedule.............................................. 127

10 TUNING THE CHASSIS ............................................... 130

10.1 Fork/shock absorber ......................................... 130

10.2 Adjusting the compression damping of the

fork ................................................................ 130

10.3 Adjusting the rebound damping of the fork ......... 131

10.4 Adjusting the spring preload of the fork.............. 132

10.5 Compression damping of the shock absorber....... 133

10.6 Adjusting the low-speed compression damping

of the shock absorber ....................................... 134

10.7 Adjusting the high-speed compression damping

of the shock absorber ....................................... 135

10.8 Adjusting the rebound damping of the shock

absorber.......................................................... 136

10.9 Adjusting the spring preload of the shock

absorber x..................................................... 136

10.10 Steering damper .............................................. 138

10.11 Adjusting the steering damper........................... 139

10.12 Vehicle level.................................................... 140

10.13 Adjusting front vehicle level x......................... 141

10.14 Adjusting the vehicle level at the rear ................ 143

10.15 Footrest position .............................................. 144

10.16 Adjusting the footrest position........................... 144

10.17 Adjusting shift lever stub .................................. 147

10.18 Adjusting the foot brake lever stub..................... 148

10.19 Adjusting shift lever ......................................... 148

10.20 Adjusting the foot brake lever............................ 152

10.21 Checking free travel of foot brake lever............... 152

10.22 Handlebar height/position ................................. 153

10.23 Adjusting the handlebar height/position ............. 154

10.24 Rear frame position.......................................... 159

10.25 Adjusting the subframe position ........................ 160

11 SERVICE WORK ON THE CHASSIS............................... 165

11.1 Raising the rear of the motorcycle with lifting

gear................................................................ 165

TABLE OF CONTENTS 6

11.2 Removing the rear of motorcycle from the lifting

gear................................................................ 165

11.3 Raising the front of the motorcycle with lifting

gear................................................................ 166

11.4 Taking the motorcycle off of the front wheel

stand .............................................................. 166

11.5 Bleeding fork legs ............................................ 167

11.6 Removing the seat ........................................... 167

11.7 Fitting the seat ................................................ 168

11.8 Mounting the helmet lock on the vehicle ............ 168

11.9 Removing the passenger seat ............................ 169

11.10 Mounting the passenger seat............................. 169

11.11 Checking for chain dirt ..................................... 170

11.12 Cleaning the chain ........................................... 170

11.13 Checking the chain tension............................... 171

11.14 Adjusting the chain tension............................... 172

11.15 Checking the chain, rear sprocket and engine

sprocket.......................................................... 174

11.16 Adjusting basic position of clutch lever .............. 177

11.17 Checking fluid level of hydraulic clutch.............. 177

11.18 Correcting fluid level of hydraulic clutch ............ 178

12 BRAKE SYSTEM ......................................................... 179

12.1 Adjusting the basic position of the hand brake

lever ............................................................... 179

12.2 Checking the front brake discs .......................... 179

12.3 Checking the rear brake disc ............................. 180

12.4 Checking the front brake fluid level ................... 181

12.5 Adding brake fluid of front brake x.................. 181

12.6 Checking the front brake linings ........................ 183

12.7 Checking the rear brake fluid level..................... 184

12.8 Adding rear brake fluid x................................ 185

12.9 Checking the rear brake linings ......................... 187

13 WHEELS, TIRES ......................................................... 188

13.1 Removing the front wheel x ............................ 188

13.2 Installing the front wheel x............................. 189

13.3 Removing the rear wheel x.............................. 192

13.4 Installing the rear wheel x .............................. 193

13.5 Checking rear hub cush drive x....................... 195

13.6 Checking the tire condition ............................... 196

13.7 Checking the tire pressure ................................ 198

14 ELECTRICAL SYSTEM ................................................. 200

14.1 Removing the battery x .................................. 200

14.2 Installing the battery x................................... 202

14.3 Recharging the battery x ................................ 203

14.4 Changing the main fuse.................................... 206

14.5 Changing the fuses of individual power

consumers....................................................... 208

14.6 Changing the low beam bulb ............................. 210

14.7 Changing the high beam bulb............................ 213

14.8 Checking the headlight setting .......................... 216

14.9 Adjusting the headlight range............................ 216

14.10 Activating/deactivating ignition key.................... 217

15 COOLING SYSTEM ...................................................... 221

15.1 Cooling system ................................................ 221

15.2 Checking the coolant level ................................ 221

15.3 Filling cooling system compensating tank........... 222

16 TUNING THE ENGINE................................................. 224

16.1 Checking the play in the throttle cable ............... 224

16.2 Adjusting the play in the throttle cable x.......... 225

TABLE OF CONTENTS 7

17 SERVICE WORK ON THE ENGINE ................................ 226

17.1 Checking the engine oil level............................. 226

17.2 Changing engine oil and filter, cleaning oil

screen x........................................................ 227

17.3 Draining engine oil, cleaning oil screens x........ 227

17.4 Removing the oil filter x................................. 230

17.5 Installing the oil filter x.................................. 232

17.6 Filling up with engine oil x ............................. 232

17.7 Adding engine oil............................................. 234

18 CLEANING, CARE ....................................................... 236

18.1 Cleaning motorcycle......................................... 236

18.2 Checks and maintenance steps for winter

operation......................................................... 238

19 STORAGE................................................................... 239

19.1 Storage ........................................................... 239

19.2 Putting into operation after storage.................... 240

20 TROUBLESHOOTING .................................................. 241

21 IMMOBILIZER BLINK CODE ........................................ 244

22 ENGINE CONTROL BLINK CODE.................................. 246

23 TECHNICAL DATA....................................................... 252

23.1 Engine ............................................................ 252

23.2 Engine tightening torques ................................. 253

23.3 Capacities ....................................................... 257

23.3.1 Engine oil ................................................... 257

23.3.2 Coolant....................................................... 257

23.3.3 Fuel ........................................................... 257

23.4 Chassis ........................................................... 257

23.5 Electrical system.............................................. 259

23.6 Tires............................................................... 260

23.7 Fork................................................................ 260

23.8 Shock absorber................................................ 261

23.9 Chassis tightening torques ................................ 262

24 SUBSTANCES ............................................................ 266

25 AUXILIARY SUBSTANCES ........................................... 270

26 STANDARDS .............................................................. 272

INDEX ............................................................................... 273

1 MEANS OF REPRESENTATION 8

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).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your

own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally

cared for by specially trained experts using the specialist tools required.

Indicates a page reference (more information is provided on the specified page).

1.2 Formats used

The typographical formats used in this document are explained below.

Specific name Identifies a proprietary name.

Name

®

Identifies a protected name.

Brand™ Identifies a brand available on the open market.

2 SAFETY ADVICE 9

2.1 Use definition - intended use

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race

courses, but not for offroad use.

Info

The motorcycle is only authorized for operation on public roads in the homologated version.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instruc-

tions are highlighted in the text and are referred to at the relevant passages.

Info

The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they

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

2 SAFETY ADVICE 10

2.3 Degrees of risk and symbols

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.

Caution

Identifies a danger that may lead to minor injuries 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.

11

2 SAFETY ADVICE 12

2.4 Overview of labels

B01298-10

2 SAFETY ADVICE 13

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 Information on locking of passenger seat

9 Information on fuel quality/engine electronics mapping

600961-01

Information on putting into operation

2 SAFETY ADVICE 14

B00592-01

Type label for Canada

600930-01

Type label for the USA

2 SAFETY ADVICE 15

B01299-01

Emission control information

B01300-01

Noise emission information

2 SAFETY ADVICE 16

600928-01

Chain tension information

B00594-01

Information on suspension setting

2 SAFETY ADVICE 17

100487-10

Information on locking of passenger seat

B00596-01

Information on fuel quality/engine electronics mapping

2.5 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 multiple similar complaints, it may open an investigation, and 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.

2 SAFETY ADVICE 18

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or

write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-

tion about motor vehicle safety from the Hotline.

2.6 Noise emission warranty

KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA 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

Phone: (440) 985–3553

www.ktmusa.com

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

Phone: (450) 441–4451 x 4250

www.ktmcanada.com

2.7 Operating noise warning

This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use.

Otherwise, the owner may become subject to penalties under the applicable ordinances.

2.8 Consumer rights

Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:

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

Phone: (440) 985–3553

www.ktmusa.com

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

Phone: (450) 441–4451 x 4250

www.ktmcanada.com

Different rights may apply, according to national or regional legislation.

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KTM 1190 RC8 R EU/UK 2009, 1190 RC8 R 2013, 1190 RC8 R US 2013 Owner's manual

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