KTM 1190 RC8 2010 Owner's manual

OWNER'S MANUAL 2010

1190 RC8 USA

Art. no. 3211524en

DEAR KTM CUSTOMER 1

DEAR KTMCUSTOMER

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 a great deal of pleasure during your ownership 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. 26) Dealer's stamp

Engine number ( p. 27)

Key number ( p. 26)

The owner's manual contained the latest information for this model at the time of going to print. 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 form part of the regular scope of delivery.

DEAR KTM CUSTOMER 2

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 AG

5230 Mattighofen, Austria

TABLE OF CONTENTS 3

TABLE OFCONTENTS

MEANS OF REPRESENTATION ............................................... 7

IMPORTANT INFORMATION ................................................... 8

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

VIEW OF VEHICLE................................................................ 22

View of vehicle, front left side............................................ 22

View of vehicle, rear right side ........................................... 24

LOCATION OF SERIAL NUMBERS ......................................... 26

Vehicle identification number/type label ............................. 26

Key number ..................................................................... 26

Engine number................................................................. 27

Fork part number.............................................................. 27

Shock absorber part number.............................................. 28

Steering damper part number ............................................ 28

CONTROLS.......................................................................... 29

Clutch lever ..................................................................... 29

Hand brake lever .............................................................. 29

Light switch ..................................................................... 30

Headlight flasher switch.................................................... 30

Turn signal switch ............................................................ 31

Horn button ..................................................................... 31

Ignition/steering lock ........................................................ 32

Emergency OFF switch...................................................... 32

Electric starter button ....................................................... 33

immobilizer...................................................................... 33

Combination instrument - overview..................................... 34

Combination instrument - function buttons on handlebar ..... 35

Combination instrument - activation and test ...................... 36

Display............................................................................ 37

Info display...................................................................... 38

Indicator lamps ................................................................ 39

Notes/warnings on the combination instrument.................... 40

Overview of ROAD mode.................................................... 44

Odometer menu ODO/Trip 1 .............................................. 45

Odometer menu ODO/Trip 2 .............................................. 46

FUELDISTANCE menu...................................................... 47

FUELRANGE menu........................................................... 48

DISTANCE TO Next Service menu...................................... 49

Overview of RACE mode .................................................... 50

LAPSTOGO menu ............................................................. 51

TOPSPEED menu ............................................................. 52

LAP/BESTLAP/LastLap menu............................................. 53

LAP/BESTLAP/TopSpeed menu.......................................... 54

Total distance menu in Race mode RACEODO..................... 55

Overview of SET‑UP mode................................................. 56

SET‑UP menu .................................................................. 58

CHANGE MODE menu ...................................................... 59

SET CLOCK menu ............................................................ 60

SETTINGS menu .............................................................. 61

SHIFT RPMS menu .......................................................... 62

LAP menu, LAP BLANK T button ....................................... 63

SET NUM LAPS menu ...................................................... 64

TRIP F RESET menu ........................................................ 65

UNITS menu.................................................................... 66

SET KM/MILES menu ....................................................... 67

SET °C/°F menu ............................................................... 68

OPTIONS menu................................................................ 69

TPMS menu..................................................................... 70

OUTERTEMP menu .......................................................... 71

TABLE OF CONTENTS 4

Displaying lap times ......................................................... 76

Displaying maximum speed ............................................... 77

Setting ROAD or RACE mode............................................. 78

Setting the clock with SET CLOCK ..................................... 78

Adjusting shift speed RPM1/2 ........................................... 79

Setting the blank time of the LAP button LAP BLANK T....... 80

Setting the number of laps SET NUM LAPS ........................ 82

Setting the fuel reserve display TRIPF RESET ..................... 83

Setting the kilometers/miles SET KM/MILES ....................... 84

Setting the temperature unit SET °C/°F .............................. 85

Switching the external temperature display on/off ................ 85

Opening the filler cap ....................................................... 87

Closing the filler cap......................................................... 88

Supporting strap............................................................... 88

Seat lock ......................................................................... 89

Helmet lock ..................................................................... 89

Passenger footrests........................................................... 90

Shift lever........................................................................ 90

Foot brake lever................................................................ 91

Side stand ....................................................................... 92

TIPS ON PUTTING INTO OPERATION .................................... 93

Advice on first use............................................................ 93

Running the engine in....................................................... 94

Loading the vehicle .......................................................... 95

RIDING INSTRUCTIONS ....................................................... 97

checks to be made before putting into operation.................. 97

Starting ........................................................................... 98

Starting up ...................................................................... 99

Shifting, riding............................................................... 100

Braking ......................................................................... 103

Stopping, parking ........................................................... 104

Refueling....................................................................... 105

SERVICE SCHEDULE.......................................................... 107

Service schedule ............................................................ 107

MAINTENANCE WORK ON FRAME AND ENGINE.................. 110

Jacking up motorcycle front............................................. 110

Taking front of motorcycle off work stand.......................... 110

Jacking up motorcycle at the rear..................................... 111

Taking the rear from the workstand .................................. 111

Fork/shock absorber........................................................ 112

Adjusting the compression damping of the fork ................. 112

Adjusting the rebound damping of the fork........................ 113

Adjusting the spring preload of the fork ............................ 114

Bleeding fork legs........................................................... 115

Compression damping of the shock absorber ..................... 116

Adjusting the low-speed compression damping of the

shock absorber ............................................................... 116

Adjusting the high-speed compression damping of the

shock absorber ............................................................... 117

Adjusting the rebound damping of the shock absorber........ 118

Adjusting the spring preload of the shock absorber x ....... 119

Steering damper............................................................. 121

Adjusting the steering damper ......................................... 121

Vehicle level .................................................................. 123

Adjusting front vehicle level x........................................ 124

Adjusting the vehicle level at the rear ............................... 126

Footrest position............................................................. 127

Adjusting footrest position............................................... 127

TABLE OF CONTENTS 5

Adjusting shift lever stub................................................. 130

Adjusting shift lever........................................................ 130

Adjusting the foot brake lever stub ................................... 134

Adjusting the foot brake lever .......................................... 135

Checking free travel of foot brake lever ............................. 135

Checking for chain dirt.................................................... 136

Cleaning the chain.......................................................... 136

Checking the chain tension ............................................. 138

Adjusting the chain tension ............................................. 139

Checking the chain, rear sprocket and engine sprocket....... 141

Checking the front brake discs......................................... 143

Checking the rear brake disc............................................ 144

Adjusting the basic position of the hand brake lever........... 145

Checking the front brake fluid level .................................. 145

Topping up brake fluid of front brake x........................... 146

Brake linings.................................................................. 147

Checking the front brake linings....................................... 148

Checking the rear brake fluid level ................................... 149

Adding rear brake fluid x .............................................. 149

Checking the rear brake linings........................................ 151

Removing the front wheel x........................................... 152

Installing the front wheel x............................................ 154

Removing the rear wheel x............................................ 156

Installing the rear wheel x............................................. 157

Checking rear hub cush drive x...................................... 160

Checking the tire condition.............................................. 160

Checking the tire pressure............................................... 162

Removing the seat .......................................................... 163

Fitting the seat............................................................... 163

Removing the passenger seat........................................... 164

Mounting the passenger seat ........................................... 164

Mounting the helmet lock on the vehicle........................... 165

Removing the battery x................................................. 165

Installing the battery x.................................................. 167

Recharging the battery x............................................... 169

Changing the main fuse .................................................. 171

Changing the fuses of individual power consumers............. 173

Changing the low beam bulb............................................ 175

Changing the high beam bulb .......................................... 178

Changing the parking light bulb ....................................... 181

Checking the headlight setting......................................... 184

Adjusting the headlamp range ......................................... 184

Activating/deactivating ignition key .................................. 185

Cooling system ............................................................... 189

Checking the coolant level............................................... 189

Filling the cooling system compensating tank.................... 190

Adjusting basic position of clutch lever............................. 192

Checking fluid level of hydraulic clutch ............................ 192

Correcting fluid level of hydraulic clutch ........................... 193

Checking the play in the throttle cable.............................. 194

Adjusting the play in the throttle cable x ........................ 195

Handlebar height............................................................ 195

Adjusting the handlebar height ........................................ 196

Rear frame position ........................................................ 198

Adjusting the rear frame position ..................................... 199

Checking the engine oil level ........................................... 203

Changing engine oil and filter, cleaning oil screen x ........ 204

Draining engine oil, cleaning oil screens x ...................... 204

TABLE OF CONTENTS 6

Removing the oil filter x................................................ 207

Installing the oil filter x ................................................ 209

Filling up with engine oil x............................................ 209

Adding engine oil ........................................................... 211

TROUBLESHOOTING.......................................................... 213

IMMOBILIZER BLINK CODE................................................ 216

ENGINE CONTROL BLINK CODE......................................... 218

CLEANING......................................................................... 224

Cleaning motorcycle ....................................................... 224

PROTECTIVE TREATMENT FOR WINTER OPERATION........... 226

Conservation for winter operation ..................................... 226

STORAGE .......................................................................... 227

Storage.......................................................................... 227

Putting into operation after storage .................................. 228

TECHNICAL DATA - ENGINE............................................... 229

Capacity - engine oil ....................................................... 230

Capacity - coolant........................................................... 230

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 231

TECHNICAL DATA - CHASSIS ............................................. 234

Lighting equipment ........................................................ 235

Tires ............................................................................. 236

Capacity - fuel................................................................ 236

TECHNICAL DATA - FORK................................................... 237

TECHNICAL DATA - SHOCK ABSORBER .............................. 238

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 240

SUBSTANCES.................................................................... 243

AUXILIARY SUBSTANCES................................................... 247

STANDARDS...................................................................... 249

INDEX ............................................................................... 250

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 INFORMATION 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 owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage and

breakage of 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. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period and inspection and maintenance intervals. Close adherence to these periods will

significantly lengthen the 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 INFORMATION 9

Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be

glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in paren-

theses. Ex: valve spring mounter (59029019000)

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 thread lock (e.g. Loctite

®

) is used for screw connections, be sure to comply with the manufacturer's specific instructions 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 repairs or servicing, the vehicle must be checked for roadworthiness.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on 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.

IMPORTANT INFORMATION 10

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-

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.

IMPORTANT INFORMATION 11

IMPORTANT INFORMATION 12

2.1Overview of labels

700380-11

IMPORTANT INFORMATION 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 Fuel evaporative system information

9 Pillion seat locking information (is on the underside of the pillion seat)

600961-01

Information on putting into operation

IMPORTANT INFORMATION 14

600932-01

Type label for Canada

600930-01

Type label for the USA

IMPORTANT INFORMATION 15

600959-01

Emission control information

600933-01

Noise emission information

IMPORTANT INFORMATION 16

600928-01

Chain tension information

100486-10

Information on suspension setting

IMPORTANT INFORMATION 17

700387-01

Fuel evaporative system information

100487-10

Pillion seat locking information (is on the underside of the pillion seat)

Notes/warnings

Pay close attention to the notes/warnings.

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 potential hazards and may therefore be injured.

IMPORTANT INFORMATION 18

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.

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.

Owner's manual

– Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to

help you operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and

how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle 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.

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