KTM 1190 RC8 R US 2012 Owner's manual

OWNER'S MANUAL 2012

1190 RC8 R USA

Art. no. 3211786en

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 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. 26) Dealer's stamp

Engine number ( p. 26)

Key number ( p. 27)

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 (vehicle differs slightly from

photo) ............................................................................. 22

View of vehicle, rear right side (vehicle differs slightly from

photo) ............................................................................. 24

SERIAL NUMBERS............................................................... 26

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

Engine number................................................................. 26

Key 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

Throttle grip..................................................................... 30

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

Headlight flasher switch.................................................... 31

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

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

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

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

Ignition/steering lock ........................................................ 33

Immobilizer ..................................................................... 34

Combination instrument - overview..................................... 35

Combination instrument - function buttons on handlebar ..... 36

Combination instrument - activation and test ...................... 37

Display............................................................................ 38

Info display...................................................................... 39

Indicator lamps ................................................................ 40

Notes/warnings on the combination instrument.................... 41

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

Distance menu 1, ODO/Trip 1/Time 1/Avs 1 ........................ 45

Distance menu 2, ODO/Trip 2/Time 2/Avs 2 ........................ 46

Gear display menu, ODO/Trip 1/Gear .................................. 47

Fuel and external temperature menu, FUEL ........................ 49

Mapping menu, ENGINE MAP ........................................... 50

Next service menu, DISTANCE TO Next Service................... 51

Overview of RACE mode .................................................... 52

Remaining laps menu, LAPSTOGO ..................................... 53

Maximum lap speed menu, TOPSPEED .............................. 54

Gear display menu, LastLap/RaceTrip/Gear ......................... 56

Fuel and external temperature menu, FUEL ........................ 57

Mapping menu, ENGINE MAP ........................................... 58

Lap times menu, LAP/BESTLAP/LapTime ........................... 59

Maximum speed menu, LAP/BESTLAP/TopSpeed ................ 60

Total distance in Race mode menu, RACEODO.................... 61

Overview of SET‑UP mode................................................. 62

SET‑UP menu .................................................................. 64

Mode menu, CHANGE MODE ............................................ 65

Time menu, SET CLOCK ................................................... 66

SETTINGS menu .............................................................. 67

Shift warning lamp menu, SHIFT RPMS ............................. 68

LAP button blank time, LAP BLANK TIME menu ................. 69

Number of laps menu, SET NUM LAPS .............................. 70

TABLE OF CONTENTS 4

Fuel reserve display menu, TRIP F RESET .......................... 71

UNITS menu.................................................................... 72

Kilometers/miles menu, SET KM/MILES ............................. 74

Temperature display menu, SET °C/°F ................................ 75

Fuel consumption menu (liters), SET FUEL CONS ............... 76

Fuel consumption menu (gallons), SET GAL US/UK............. 77

Additional functions menu, OPTIONS................................. 78

Quick shifter menu, OPTION QKSHIFT............................... 79

External temperature display menu, OPTION OUTTEMP....... 80

Tire pressure monitor menu, OPTION TPMS........................ 81

Adjusting the mapping of the engine electronics

ENGINE MAP................................................................... 90

Displaying lap times ......................................................... 91

Displaying maximum speed ............................................... 91

Setting ROAD or RACE mode............................................. 92

Setting the clock with SET CLOCK ..................................... 93

Adjusting the shift speed RPM1/2...................................... 93

Setting the blank time of the LAP button

LAP BLANK TIME ............................................................ 95

Setting the number of laps SET NUM LAPS ........................ 96

Setting the fuel reserve display TRIP F RESET .................... 97

Setting the kilometers/miles SET KM/MILES ....................... 98

Setting the temperature unit SET °C/°F .............................. 99

Setting the unit of fuel consumption (liters)

SET FUEL CONS ............................................................ 100

Unit of fuel consumption (gallons) SET GAL US/UK........... 101

Switching the external temperature display on/off .............. 102

Opening the filler cap ..................................................... 103

Closing the filler cap....................................................... 105

Supporting strap............................................................. 105

Passenger footrests......................................................... 106

Shift lever...................................................................... 106

Foot brake lever.............................................................. 107

Side stand ..................................................................... 108

Seat lock ....................................................................... 108

Helmet lock ................................................................... 109

PREPARING FOR USE........................................................ 110

Advice on first use.......................................................... 110

Running the engine in..................................................... 111

Loading the vehicle ........................................................ 111

RIDING INSTRUCTIONS ..................................................... 114

Checks and maintenance measures when preparing for

use ............................................................................... 114

Starting ......................................................................... 115

Starting off .................................................................... 116

Shifting, riding............................................................... 117

Braking ......................................................................... 120

Stopping, parking ........................................................... 121

Refueling....................................................................... 122

SERVICE SCHEDULE.......................................................... 125

Service schedule ............................................................ 125

TUNING THE CHASSIS....................................................... 128

Fork/shock absorber........................................................ 128

Adjusting the compression damping of the fork ................. 128

Adjusting the rebound damping of the fork........................ 129

Adjusting the spring preload of the fork ............................ 130

Compression damping of the shock absorber ..................... 131

Adjusting the low-speed compression damping of the

shock absorber ............................................................... 132

TABLE OF CONTENTS 5

Adjusting the high-speed compression damping of the

shock absorber ............................................................... 133

Adjusting the rebound damping of the shock absorber........ 134

Adjusting the spring preload of the shock absorber x ....... 134

Steering damper............................................................. 136

Adjusting the steering damper ......................................... 137

Vehicle level .................................................................. 138

Adjusting front vehicle level x........................................ 139

Adjusting the vehicle level at the rear ............................... 141

Footrest position............................................................. 142

Adjusting the footrest position ......................................... 142

Adjusting shift lever stub................................................. 145

Adjusting the foot brake lever stub ................................... 146

Adjusting shift lever........................................................ 146

Adjusting the foot brake lever .......................................... 150

Checking free travel of foot brake lever ............................. 150

Handlebar height/position ............................................... 151

Adjusting the handlebar height/position............................ 152

Rear frame position ........................................................ 157

Adjusting the rear frame position ..................................... 158

SERVICE WORK ON THE CHASSIS...................................... 163

Raising the front of the motorcycle with lifting gear ........... 163

Taking the motorcycle off of the front wheel stand ............. 163

Raising the rear of the motorcycle with lifting gear............. 164

Removing the rear of motorcycle from the lifting gear......... 164

Bleeding fork legs........................................................... 165

Removing the seat .......................................................... 165

Fitting the seat............................................................... 166

Mounting the helmet lock on the vehicle........................... 166

Removing the passenger seat........................................... 167

Mounting the passenger seat ........................................... 167

Checking for chain dirt.................................................... 168

Cleaning the chain.......................................................... 168

Checking the chain tension ............................................. 169

Adjusting the chain tension ............................................. 170

Checking the chain, rear sprocket and engine sprocket....... 172

Adjusting basic position of clutch lever............................. 175

Checking fluid level of hydraulic clutch ............................ 175

Correcting fluid level of hydraulic clutch ........................... 176

BRAKES............................................................................ 177

Adjusting the basic position of the hand brake lever........... 177

Checking the front brake discs......................................... 177

Checking the rear brake disc............................................ 178

Checking the front brake fluid level .................................. 179

Adding brake fluid of front brake x................................. 179

Checking the front brake linings....................................... 181

Checking the rear brake fluid level ................................... 182

Adding rear brake fluid x .............................................. 183

Checking the rear brake linings........................................ 184

WHEELS, TIRES ................................................................ 186

Removing the front wheel x........................................... 186

Installing the front wheel x............................................ 187

Removing the rear wheel x............................................ 190

Installing the rear wheel x............................................. 191

Checking rear hub cush drive x...................................... 193

Checking the tire condition.............................................. 194

Checking the tire pressure............................................... 196

TABLE OF CONTENTS 6

ELECTRICAL SYSTEM ........................................................ 198

Removing the battery x................................................. 198

Installing the battery x.................................................. 200

Recharging the battery x............................................... 201

Changing the main fuse .................................................. 204

Changing the fuses of individual power consumers............. 206

Changing the low beam bulb............................................ 208

Changing the high beam bulb .......................................... 211

Checking the headlight setting......................................... 214

Adjusting the headlight range .......................................... 214

Activating/deactivating ignition key .................................. 215

COOLING SYSTEM ............................................................. 219

Cooling system ............................................................... 219

Checking the coolant level............................................... 219

Filling cooling system compensating tank ......................... 220

TUNING THE ENGINE ........................................................ 222

Checking the play in the throttle cable.............................. 222

Adjusting the play in the throttle cable x ........................ 223

SERVICE WORK ON THE ENGINE ....................................... 224

Checking the engine oil level ........................................... 224

Changing engine oil and filter, cleaning oil screen x ........ 225

Draining engine oil, cleaning oil screens x ...................... 225

Removing the oil filter x................................................ 228

Installing the oil filter x ................................................ 230

Filling up with engine oil x............................................ 230

Adding engine oil ........................................................... 232

CLEANING, CARE .............................................................. 234

Cleaning motorcycle ....................................................... 234

Checks and maintenance steps for winter operation ........... 235

STORAGE .......................................................................... 237

Storage.......................................................................... 237

Putting into operation after storage .................................. 238

TROUBLESHOOTING.......................................................... 239

IMMOBILIZER BLINK CODE................................................ 242

ENGINE CONTROL BLINK CODE......................................... 244

TECHNICAL DATA - ENGINE............................................... 251

Capacity - engine oil ....................................................... 252

Capacity - coolant........................................................... 253

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 254

TECHNICAL DATA - CHASSIS ............................................. 257

Lighting equipment ........................................................ 258

Tires ............................................................................. 259

Capacity - fuel................................................................ 259

TECHNICAL DATA - FORK................................................... 260

TECHNICAL DATA - SHOCK ABSORBER .............................. 261

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 263

SUBSTANCES.................................................................... 266

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

STANDARDS...................................................................... 272

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

MEANS OF REPRESENTATION 7

Symbols used

The symbols used are explained below.

Indicates an expected reaction (e.g. to a work step or a function).

Indicates an unexpected reaction (e.g. to a work step or a function).

All work marked with this symbol requires 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 serviced opti-

mally by specially trained experts using the specialist tools required.

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

Formats used

The typographical and other formats used are explained below.

Specific name Identifies a proprietary 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.

Service

A prerequisite for fault-free operation and avoiding premature wear is compliance with the service, 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.

Make sure to comply with the specified run-in times and service intervals. Close adherence to these periods will significantly lengthen the

service life of your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's

service record and in the KTM dealer.net; otherwise, all warranty claims will be void. 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.

11

IMPORTANT INFORMATION 12

2.1Overview of labels

B00569-10

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 Information on locking of passenger seat

10 Information on fuel quality/engine electronics mapping

600961-01

Information on putting into operation

IMPORTANT INFORMATION 14

B00592-01

Type label for Canada

600930-01

Type label for the USA

IMPORTANT INFORMATION 15

C00130-01

Emission control information

C00128-01

Noise emission information

IMPORTANT INFORMATION 16

600928-01

Chain tension information

B00594-01

Information on suspension setting

IMPORTANT INFORMATION 17

C00129-01

Fuel evaporative system information

100487-10

Information on locking of passenger seat

IMPORTANT INFORMATION 18

B00596-01

Information on fuel quality/engine electronics mapping

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.

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