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KTM 1190 RC8 R 2012, 1190 RC8 R US 2012, 1190 RC8 R USA Owner's manual

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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
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÃœV 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.
Brandâ„¢ 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.
/