KTM Motorcycle 1190 RC8 User Manual

Check the valve clearance and adjust if necessary.

Replace the spark plugs.

Check the engine fixing screws and other engine screws accessible

from outside to ensure that they are tight.

Check the clutch.

Clean the oil jet for clutch lubrication.

Read out the status query and fault memory with KTM DIA.

Check bellows for tears and leaks, and check the linkage of the throt-

tle valve spigot for freedom of movement.

^{Change the engine oil and filter, clean the oil scree}x^n.

•

Fuel injection

•

rect routing.

Check hoses of vacuum sensors, SLS hoses and vent hoses for dam-

age, correct routing and leaks.

^{Check the ca}x^{ble harness of the throttle valve body for damage and cor-}

•

Check fuel pressure.

Check the cooling system for leaks.

^{Check the fuel hose f}x^{or damage, correct routing and leaks.}

Attachments

•

Check the water pump for leaks (visual check).

Check the coolant level. ( S. 172)

•

Check the antifreeze.

Check the functioning of the radiator fan.

•

the exhaust holders are tight.

^{Check the exhaust system for}x^{leaks and correct fitting and check that}

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GREASING AND SERVICE TABLE

K10N

K75A

K150A

J1A

•

J2A

•

Attachments

Check bowden cables for damage, smooth operation, kink-free routing

and adjustment.

Check the fluid level of the hydraulic clutch. ( S. 175)

•

box.

Drain the drainage hose of the air filter box.

^Checx^{k the air filter and change if necessary. Clean the air filter}

•

Check cables for damage and kink-free routing.

Check the headlight adjustment. ( S. 167)

•

Check the functioning of the electrical equipment.

Check screws and for tightness.

^{Check the fairing parts for dama}x^{ge and breakage.}

Brakes

Check the front brake linings. ( S. 132)

Check the rear brake linings. ( S. 135)

Check the front brake discs. ( S. 128)

Check the rear brake disc. ( S. 129)

Check the brake fluid level of the front brake. ( S. 130)

Check the rear brake fluid level. ( S. 133)

•

Change brake fluid.

•

Check that brake lines are undamaged and free of leaks.

Check the braking.

Check screws and guide pins of the brake system for tightness.

^{Check the free play}x^{of the foot brake lever.}

Chassis

•

Check the shock absorber and fork for leaks and function.

Bleed fork legs. ( S. 100)

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GREASING AND SERVICE TABLE

K10N

K75A

K150A

J1A

J2A

Chassis

•

Check the steering head bearing and adjust if necessary.

Check the swingarm bearing.

Check deflector.

Check the eccentric shaft adjustment.

•

Check all screws to make sure they are tight.

Check the tire condition. ( S. 143)

Checking the tire air pressure. ( S. 145)

Check the chain wear. ( S. 127)

Wheels

•

ensure that they are tight.

^{Check the rear sprocket / e}x^{ngine sprocket / chain sliding guard to}

Check the rear sprocket / engine sprocket for wear. ( S. 126)

Check the chain tension. ( S. 123)

•

Clean the chain. ( S. 122)

•

Check chain sliding guard. ( S. 128)

Check wheel bearings for play.

•

Check the rear hub shock absorbers.

S. 143)

K10N: after 1,000 km (621.4 mi)

K75A: every 7,500 km (4,660 mi)

K150A: every 15,000 km (9,320 mi) / after every sporting use

J1A: annually

J2A: every 2 years

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GREASING AND SERVICE TABLE

K150A K300A

J1A

J2A

•

Completely service fork.

Completely service shock absorber.

•

Clean and grease the steering head bearing and sealing elements.

Clean battery poles and treat with contact grease.

•

Change the coolant.

K150A: every 15,000 km (9,320 mi) / after every sporting use

K300A: every 30,000 km (18,640 mi)

J1A: annually

J2A: every 2 years

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MAINTENANCE WORK ON CHASSIS AND ENGINE

9MAINTENANCE WORK ON CHASSIS AND ENGINE

Jacking up motorcycle front

Note

Danger of damageꢀDanger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

–

Jack up the motorcycle rear end. ( S. 96)

Move the handlebar to the straight-ahead position. Align the work stand at the front

with the adapters to the fork legs.

Work stand front (61029055300)

Info

Always jack up the rear of the motorcycle first.

–

Jack up the motorcycle at the front.

700250-01

Note

Danger of damageꢀDanger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

–

Secure the motorcycle against falling over.

Remove the work stand from the front.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

Note

Danger of damageꢀDanger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

–

Insert the work stand adapter in the rear of the work stand.

Work stand adapter (61029055120)

Work stand rear (61029055100)

Stand the motorcycle upright, align the work stand to the link fork and the adapters,

and jack up the motorcycle.

700251-01

Note

Danger of damageꢀDanger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

–

Secure the motorcycle against falling over.

Remove the work stand from the rear and lean the vehicle on the sidestand.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

The fork and the shock absorber offer many options of adapting the chassis to your riding

style and the payload.

Info

To help you adapt the vehicle, we have summarized our findings in Table . You

will find the table on the underside of the seat. For all damping steps, start from

the maximum screwed-in position with the highest damping factor and set to the

specified values. Do not use excessive force to turn the adjusting screws against the

stop, and take the last percepticle click as the end position.

700252-01

These adjustments should be understood as a guideline and should always be the basis

of your own personal chassis adaptation. Do not change the adjustments at random or by

more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly

at high speeds.

djusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when

the load shifts very fast. It gives the rider good feedback about the road conditions.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

–

Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws are located at the bottom end of the fork legs.

Make the same adjustment on both fork legs.

–

Turn back counterclockwise the number of clicks corresponding to the fork type.

Guideline

Compression damping

700253-01

Comfort

Standard

Sport

15 clicks

10 clicks

5 clicks

full payload

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

Info

The hydraulic rebound damping determines the fork suspension behavior.

An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the

zero position.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

–

Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

–

Turn back counterclockwise the number of clicks corresponding to the fork type.

Guideline

Rebound damping

Comfort

Standard

Sport

15 clicks

10 clicks

5 clicks

Full payload

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

700347-01

Info

The spring preload defines the initial situation of the spring process of the fork.

An optimally adjusted spring preload is adapted to the rider's weight and ensures a compromise between easy handling and stabil-

ity.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

100

–

Turn the adjusting spindles  clockwise until they stop.

Info

The adjusting spindles are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

–

Turn back counterclockwise the number of turns corresponding to the fork type.

Guideline

Spring preload - Preload Adjuster

Comfort

Standard

Sport

5 turns

3 turns

full payload

Info

Turn clockwise to increase preload, turn counterclockwise to reduce spring

preload.

Changing the spring preload has no influence on the rebound damping although

the adjusting screws turn during the adjustment work. However, you should also

adjust the rebound damping when you alter the spring preload.

700348-01

–

Lean the motorcycle on the side stand.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

101

–

Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

Mount and tighten bleeder screws.

–

Info

Perform this action on both fork legs.

700259-01

.10

The shock absorber can coordinate the compression damping separately in the low  and

high  speed range (Dual Compression Control).

The term low and high speed refers to the movement of the shock absorber during compres-

sion and not the riding speed of the motorcycle.

The low and high speed adjustment works for all areas.

700340-01

.11

djusting the low-speed compression damping of the shock absorber

Danger

Danger of accidentsꢀThe shock absorber is under high pressure.

–

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

102

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

–

Turn the adjusting screw  clockwise with a screwdriver up to the last perceptible

click.

Info

Do not loosen nut !

–

Turn back counterclockwise the number of clicks corresponding to the shock absorber

type.

Guideline

700255-01

Compression damping, low-speed

Comfort

Standard

Sport

20 clicks

15 clicks

10 clicks

full payload

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

103

.12

djusting high-speed compression damping of the shock absorber

Danger

Danger of accidentsꢀThe shock absorber is under high pressure.

–

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

–

Turn the adjusting screw  clockwise with an open-ended spanner until it stops.

Info

Do not loosen nut !

–

Turn back counterclockwise the number of turns corresponding to the shock absorber

type.

Guideline

Compression damping, high-speed

700256-01

Comfort

Standard

Sport

2 turns

1.5 turns

1 turn

full payload

1 turn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

104

.13

djusting rebound damping of the shock absorber

Danger

Danger of accidentsꢀThe shock absorber is under high pressure.

–

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

–

Turn the adjusting screw  clockwise up to the last perceptible click.

Turn back counterclockwise the number of clicks corresponding to the shock absorber

type.

Guideline

Rebound damping

Comfort

Standard

Sport

15 clicks

10 clicks

5 clicks

700257-01

full payload

10 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

.14

djusting spring preload of shock absorber

Warning

Danger of accidentsꢀModifications to the chassis can seriously alter the vehicle's handling characteristics.

–

Following modifications, ride slowly at first to get the feel of the new handling characteristics.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

105

Info

The spring preload defines the initial situation of the spring process on the shock absorber.

An optimally adjusted spring preload is adapted to the rider's weight and ensures a compromise between easy handling and stabil-

ity.

–

Take the weight off the rear wheel and swingarm.

Info

The spring preload can be adjusted correctly only if the rear wheel and the

swingarm are fully relieved of weight.

–

Loosen screw  two turns, but do not remove.

700341-10

Turn the adjusting ring anticlockwise with the toolset wrench until the spring is com-

pletely relaxed.

Hook wrench (69012022000)

Extension (60012060000)

700342-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

106

–

Turn the adjusting ring clockwise and tension it to the specified value.

Guideline

Spring preload

Comfort

6 mm (0.24 in)

8 mm (0.31 in)

Standard

Sport

full payload

Info

Turn clockwise to increase preload, turn counterclockwise to reduce spring

preload.

–

Tighten screw .

Guideline

Remaining chassis screws

5 Nm (3.7 lbf ft)

700341-11

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MAINTENANCE WORK ON CHASSIS AND ENGINE

107

.15

The steering damper suppresses shocks to the steering arising from acceleration on uneven

ground at high speed or when the load is temporarily taken from the front wheel.

The steering damper is adjusted to suit the manner of driving and the road conditions. For

high speeds, an adjustment with high damping can be chosen in order to use the steering

damping function optimally. In slow, tight bends, intensive damping can negatively affect

handling and steering precision, so the damping should be set to low.

700339-01

.16

djusting the steering damper

Info

The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load.

In contrast to other damping elements, the steering damper is adjusted with the damping element open.

–

Turn the adjusting screw  anticlockwise towards "–" as far as the last perceptible

click.

700339-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

108

–

Adjust the steering damper according to your riding style and the road conditions by

turning the adjust screw clockwise towards "+".

Guideline

Steering damper adjustment range

Recommended range for use

Standard

1… 32 clicks

1… 20 clicks

1 click

Info

Do not change the adjustment of the steering damper during the journey!

After adjusting the steering damper, check the steering for smooth operation,

making sure that the handlebar can be moved from extreme left to extreme right

without a tendency to lock.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

109

.17

Warning

Danger of accidentsꢀModifications to the chassis can seriously alter the vehicle's

handling characteristics.

–

Following modifications, ride slowly at first to get the feel of the new handling

characteristics.

The vehicle level can be adjusted at the front by means of the fork leg clamp and at the

rear by the eccentric shaft.

The fork legs can be clamped at three positions in the triple clamps.

Upper triple clamp flush with 0 mm (0 in)

upper edge of fork legs

Upper triple clamp flush with 2.5 mm (0.098 in)

1st ring of fork legs

Upper triple clamp flush with 5 mm (0.2 in)

2nd ring of fork legs (stan-

dard)

The chassis height can be adjusted steplessly by turning the eccentric shaft.

Chassis height difference

7 mm (0.28 in)

700333-01

HIGH - LOW

Maximum adjustment range

180°

between HIGH - LOW

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MAINTENANCE WORK ON CHASSIS AND ENGINE

110

.18

djusting vehicle level, front

Warning

Danger of accidentsꢀModifications to the chassis can seriously alter the vehicle's handling characteristics.

Following modifications, ride slowly at first to get the feel of the new handling characteristics.

–

Loosen the clamp screws of the lower and upper triple clamps and of the handlebar

stub.

Info

Loosen the clamp screws far enough to prevent damage to the lacquer when the

fork legs are moved.

Make the adjustments first on one fork leg and then on the other. If the clamp

screws of both fork legs are loosened, the vehicle sags towards the front.

700352-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

111

–

The fork legs can be fixed at three different positions.

Guideline

Upper triple clamp flush with upper edge 0 mm (0 in)

of fork legs

Upper triple clamp flush with 1st ring of

fork legs

2.5 mm (0.098 in)

Upper triple clamp flush with 2nd ring of 5 mm (0.2 in)

fork legs (standard)

700353-01

Info

The standard adjustment is optimal for handling the vehicle. When the fork is

compressed, the chassis setting changes, the vehicle becomes more stable, but

handling is more difficult.

–

Tighten the screws.

Guideline

Screw, top triple clamp

Screw, bottom triple clamp

Screw, handlebar stub

17 Nm (12.5 lbf ft)

15 Nm (11.1 lbf ft)

20 Nm (14.8 lbf ft)

Repeat the adjustment on the other fork leg.

.19

Warning

Danger of accidentsꢀModifications to the chassis can seriously alter the vehicle's handling characteristics.

–

Following modifications, ride slowly at first to get the feel of the new handling characteristics.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

112

–

Loosen screw  but do not remove it.

700331-01

–

Turn the eccentric shaft  to the desired position using the tool from the tool set.

Guideline

Standard

LOW

Maximum adjustment range between

180°

HIGH - LOW

Open end wrench SW 38 (69012021000)

Info

700332-01

You can adjust the chassis height in both directions.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

113

–

Tighten screw .

Guideline

Remaining chassis screws

25 Nm (18.4 lbf ft)

700334-01

.20

ootrest position

The adjustable footrest system enables an individual setting of the footrest height and an

individual adjustment of the operating elements.

The lower footrest position enables a more comfortable knee angle, the upper footrest posi-

tion a sporting sitting position and more forward-leaning freedom for use in racing.

700328-01

.21

djusting footrest position

Info

The footrest position must be identical on the left and the right.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

114

–

Remove screws .

700307-01

700308-01

700306-01

Position the footrest bracket with spacers  and screws.

Guideline

Standard

Lower position

Info

The adjustable footrest bracket enables a more comfortable lower footrest posi-

tion or a sporting upper footrest position.

Mount and tighten screws.

Guideline

Screw, front footrest bracket M8

25 Nm

Loctite^®243™

(18.4 lbf ft)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

115

–

Repeat adjustment work on the footrest bracket on the other side.

Adjust the shift lever. ( S. 116)

Adjust the footbrake pedal. ( S. 121)

700309-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

116

.22

djusting shift lever stub

–

Remove the screw  with the shift lever stub.

Position the shift lever stub with the screw in one of the holes  according to the

desired lever length.

Guideline

Standard

Central hole

–

Tighten screw.

Guideline

Screw, shift lever stub

10 Nm

Loctite^®243™

(7.4 lbf ft)

700304-01

.23

djusting shift lever

Info

The footrest system offers many ways of adjusting the shift lever to your riding style and requirements.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

117

–

Remove screws  and take off the shift rod.

The length of the shift rod can be adjusted by means of the screw thread.

Guideline

–

Shift rod

115… 130 mm (4.53… 5.12 in)

–

Loosen the counter nuts .

Adjust the shift shaft.

Info

Make the same adjustments on both sides.

After the counter nuts have been tightened, the bearings of the shift shaft must

be central and aligned identically to each other in order to ensure freedom of

movement in the bearing shells.

At least 5 screw threads must be screwed into the seating.

–

Tighten the counter nuts.

700343-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

118

–

The shift rod can be mounted both on the shift lever variably at an upper or lower posi-

tion, and on the reverse gear change of the shift shaft in two different positions.

Guideline

Standard 

Shift lever: lower drill hole,

shift shaft: lower drill hole

Shift power low, shift way long 

Shift power high, shift way short 

Shift lever: lower drill hole,

shift shaft: upper drill hole

Shift lever: upper drill hole,

shift shaft: lower drill hole

–

Position the shift rod.

Tighten the screws.

Guideline

Screw, shift rod

12 Nm

Loctite^®243™

(8.9 lbf ft)

400479-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

119

–

The position of the shift lever can be greatly varied, depending on the length of the shift

rod and the drill holes selected. As seen from the footrest, there is either a high position

of the shift lever  or a low position of the shift lever .

Info

If you turn the reverse shift shaft 2 teeth on the serration of the shift shaft, you

can adjust the footrest system optimally for the upper footrest position.

–

After adjusting the shift lever, conduct a function test. There must be a minimum dis-

tance between the moving parts of the shift lever and other parts of the vehicle.

Guideline

Minimum distance

5 mm (0.2 in)

700344-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

120

.24

–

Remove the screw  with the footbrake pedal stub.

Position the footbrake pedal stub with the screw in one of the holes  according to the

desired lever length.

Guideline

Standard

Central hole

–

Tighten screw.

Guideline

Screw, footbrake pedal stub M6

10 Nm

Loctite^®243™

(7.4 lbf ft)

700305-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

121

.25

–

Use the tool to press in the anti-rotation lock , then turn the piston rod .

Info

The range of adjustment is limited.

–

Remove the tool.

The spring tension on the anti-rotation lock is released and the hex nut is locked.

700345-01

–

Check the footbrake pedal setting.

Info

Position  of the shift lever can vary considerably, depending on the setting.

700346-01

.26

hecking for chain dirt

–

Check the chain for loose dirt.

If the chain is very dirty:

Clean the chain. ( S. 122)

–

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MAINTENANCE WORK ON CHASSIS AND ENGINE

122

.27

leaning the chain

Warning

Danger of accidentsꢀOil or grease on the tires reduces their grip.

–

Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.

–

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The service life of the chain depends largely on its maintenance.

–

Clean the chain regularly.

Rinse off loose dirt with a soft jet of water.

Remove old grease remains with chain cleaner.

Chain cleaner ( S. 224)

–

After drying, apply chain spray.

Onroad chain spray ( S. 225)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

123

.28

hecking the chain tension

Warning

Danger of accidentsꢀDanger caused by incorrect chain tension.

–

If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings

in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture

or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or

the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

–

Lean the motorcycle on the side stand.

Shift into neutral.

In the area before where the chain passes through the link fork, push the chain down-

wards and measure the chain tension .

Info

The lower chain section  must be taut.

Chain wear is not always even, so you should repeat this measurement at differ-

ent chain positions.

700322-01

Chain tension

If the chain tension does not meet specifications:

Adjust the chain tension. ( S. 124)

15… 20 mm (0.59… 0.79 in)

–

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MAINTENANCE WORK ON CHASSIS AND ENGINE

124

.29

djusting the chain tension

Warning

Danger of accidentsꢀDanger caused by incorrect chain tension.

–

If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings

in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture

or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or

the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

–

Check the chain tension. ( S. 123)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

125

–

Loosen nut .

Loosen nuts .

Adjust chain tension by turning the adjustment screws  on the left and right.

Guideline

Chain tension

15… 20 mm (0.59… 0.79 in)

Turn the adjusting screws  on the left and right so that the markings on the left and

right chain adjuster  are in the same position in relation to the reference marks .

The rear wheel is then correctly aligned.

Info

The lower chain section must be taut.

Chain wear is not always even, so you should check the setting at different chain

positions.

–

Tighten nuts .

Make sure that the chain adjusters  are on the adjusting screws .

Tighten nut .

Guideline

Nut, rear wheel spindle

M25x1.5

90 Nm

Thread greased

700323-01

(66.4 lbf ft)

Info

The wide adjustment range of the chain adjuster (35mm / 1.38") allows differ-

ent secondary transmission ratios to be used with the same chain length.

The chain adjusters  can be turned through 180°.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

126

.30

–

Check the rear sprocket / engine sprocket for wear.

If the rear sprocket / engine sprocket are worn:

–

Change the rear sprocket / engine sprocket, chain and chain sliding guard.

Info

The rear sprocket, engine sprocket, chain and chain sliding guard should

always be changed together.

100132-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

127

.31

–

Engage neutral gear.

Pull the lower chain section with specified weight .

Guideline

Weight, chain wear measurement

15 kg (33 lb.)

–

Measure distance  of 18 chain links in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at differ-

ent chain positions.

Maximum distance  at the longest

272 mm (10.71 in)

chain section

If the distance  is greater than the specified measurement:

–

Change the rear sprocket / engine sprocket, chain and chain sliding guard.

Info

New chains wear out faster on old, worn sprockets.

For safety reasons, the chain has no chain joint. Always have the chain

changed in an authorized KTM-RC8 workshop, where they have the nec-

essary special tools.

700303-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

128

.32

–

Check the chain sliding guard for wear at the opening.

If the rivets  of the chain are no longer visible at the lower edge  of the opening

of the chain sliding guard:

–

Change the chain sliding guard.

700351-01

.33

hecking front brake discs

Warning

Danger of accidentsꢀReduced braking effect caused by worn brake discs.

Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop.

–

Check the thickness of the brake disc in several places to see if it conforms to measure-

ment .

Info

Wear reduces the thickness of the brake discs in area  of the brake discs.

Brake discs - wear limit

front

4.0 mm (0.157 in)

If the brake disc thickness is less than the specified value:

100135-10

–

Change the brake discs.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

129

.34

hecking rear brake disc

Warning

Danger of accidentsꢀReduced braking effect caused by worn brake discs.

–

Have worn brake discs replaced immediately in an authorized KTM-RC8 workshop.

–

Check the thickness of the brake disc in several places to see if it conforms to measure-

ment .

Info

Wear reduces the thickness of the brake disc in area  of the brake disc.

Brake discs - wear limit

rear

4.5 mm (0.177 in)

If the brake disc thickness is less than the specified value:

400480-10

–

Change brake disc.

.35

–

Pull the brake lever forwards.

Adjust the neutral position of the handbrake lever to your hand position by turning the

adjusting screw .

Info

Do not make any adjustments while riding!

700260-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

130

.36

hecking brake fluid level of front brake

Warning

Danger of accidentsꢀFailure of brake system.

–

If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely

worn out. Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey.

Warning

Danger of accidentsꢀReduced braking effect caused by old brake fluid.

–

Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM-RC8 workshop.

–

The brake fluid level must not fall below the MIN marking  when the brake fluid reser-

voir is vertical.

If the brake fluid is below the MIN marking:

–

Top up the brake fluid of the front brake.

S. 130)

700261-01

.37

opping up brake fluid of front brake

Warning

Danger of accidentsꢀFailure of brake system.

–

If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely

worn out. Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

131

Warning

Skin irritationsꢀBrake fluid can cause skin irritation on contact.

–

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsꢀReduced braking effect caused by old brake fluid.

–

Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM-RC8 workshop.

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for

DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

–

Loosen screw.

Remove cover  with membrane .

Top up the brake fluid to MAX level.

Brake fluid DOT 4 / DOT 5.1 ( S. 221)

–

Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

700262-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

132

.38

The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the

brake linings are entered in the homologation documents.

Info

Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles. The structure and friction

coefficient of the brake linings, and therefore the brake power, can vary considerably from the original KTM brake linings. If brake

linings other than those supplied as originals are used, there is no guarantee that they correspond to the original homologation. The

vehicle then no longer corresponds to the condition at delivery and the guarantee is no longer valid.

.39

hecking the front brake linings

Warning

Danger of accidentsꢀReduced braking caused by worn brake linings.

–

Have worn brake linings replaced immediately in an authorized KTM-RC8 workshop.

Note

Danger of accidentsꢀReduced braking due to damaged brake discs.

–

If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly

reduced and the brake discs are destroyed.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

133

–

Check the brake linings for minimum thickness .

Minimum thickness 

≥ 1 mm (≥ 0.04 in)

^{If the minimum thickness is less th}x^{an specified:}

–

Change the front brake linings.

700263-01

.40

Warning

Danger of accidentsꢀFailure of brake system.

–

If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely

worn out. Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey.

Warning

Danger of accidentsꢀReduced braking effect caused by old brake fluid.

–

Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM-RC8 workshop.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

134

–

Stand the vehicle upright.

–

Check the brake fluid level of the brake fluid reservoir.

If the fluid level reaches the MIN mark :

–

Top up the rear brake fluid.

S. 134)

700264-01

.41

opping up rear brake fluid

Warning

Danger of accidentsꢀFailure of brake system.

–

If the brake fluid level falls below the MIN mark, there may be a leak in the brake system or the brake linings are completely

worn out. Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey.

Warning

Skin irritationsꢀBrake fluid can cause skin irritation on contact.

–

Avoid contact with skin and eyes, and keep out of the reach of children.

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsꢀReduced braking effect caused by old brake fluid.

–

Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized KTM-RC8 workshop.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

135

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for

DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

–

Stand the vehicle upright.

Remove screw cover  with membrane .

Top up the brake fluid to MAX level.

Brake fluid DOT 4 / DOT 5.1 ( S. 221)

Refit screw with membrane.

–

Info

Clean up overflowed or spilt brake fluid immediately with water.

700265-01

.42

Warning

Danger of accidentsꢀReduced braking caused by worn brake linings.

–

Have worn brake linings replaced immediately in an authorized KTM-RC8 workshop.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

136

Note

Danger of accidentsꢀReduced braking due to damaged brake discs.

–

If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly

reduced and the brake discs are destroyed.

–

Check the brake linings for minimum thickness .

Minimum thickness 

≥ 1 mm (≥ 0.04 in)

If the minimum thickness is less than specified:

–

Change the rear brake linings.

700266-01

.43

emoving front wheel

–

Jack up the motorcycle rear end. ( S. 96)

Jack up the motorcycle at the front. ( S. 95)

Remove the screws  from both brake calipers.

Press back the brake linings with a light lateral tilting of the brake calipers on the brake

disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.

Info

Do not pull the handbrake lever when the brake calipers are removed.

700271-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

137

–

Loosen screws  and .

–

Unscrew screw  about 6 turns, press your hand on the screw to push the wheel spin-

dle out of the fork stub. Remove screw .

Warning

Danger of accidentsꢀReduced braking effect caused by damaged brake discs.

–

Always lay the wheel down in such a way that the brake discs are not dam-

aged.

700272-10

–

Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the

fork.

.44

itting front wheel

Warning

Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.

–

Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

–

Clean screw  and wheel spindle .

Lift the front wheel into the fork, position it, and insert the wheel spindle.

Mount and tighten screw .

200487-10

Guideline

Screw, front wheel spindle

M25x1.5

45 Nm (33.2 lbf ft)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

138

–

Position the brake calipers and check that the brake linings are seated correctly.

–

Mount and tighten screws .

Guideline

Screw, front brake caliper

M10x1.25

45 Nm

Loctite^®243™

(33.2 lbf ft)

–

Operate the hand brake lever several times until the brake pads are lying correctly on

the brake disc.

–

Take the front of the motorcycle off the work stand. ( S. 95)

Take the rear of the motorcycle off the work stand. ( S. 96)

Pull the front brake and compress the fork powerfully a few times.

700271-12

The fork legs straighten.

Fully tighten screws .

Guideline

–

Screw, fork stub

15 Nm (11.1 lbf ft)

700272-11

.45

emoving rear wheel

–

Jack up the motorcycle rear end. ( S. 96)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

139

–

Remove nut . Remove chain adjuster . Withdraw the wheel spindle .

700311-01

–

Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.

Pull the rear whell backwards until the brake caliper support  hangs free between the

brake disc and the wheel rim.

Warning

Danger of accidentsꢀReduced braking effect caused by damaged brake discs.

–

Always lay the wheel down in such a way that the brake discs are not dam-

aged.

700312-01

–

Take the rear wheel carefully out of the swingarm without damaging the rim and/or

brake disc.

Info

Do not operate the foot brake when the rear wheel is removed.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

140

.46

itting the rear wheel

Warning

Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

–

Warning

Danger of accidentsꢀNo braking effect when operating the rear brake.

–

After installing the rear wheel, always operate the footbrake until the pressure point is reached.

–

Check the rear hub shock absorbers.

S. 143)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

141

–

Remove bushing  and bushing . Clean and grease the roll surfaces of the bushing

and the shaft seal rings.

Long-life grease ( S. 224)

–

Fit the bushings.

Clean the thread of the wheel spindle and nut.

Clean the contact areas of the brake caliper support and swingarm.

700313-01

–

Push the brake caliper support  completely to the rear.

Position the rear wheel, and position the brake caliper support between the rim and the

brake disc.

–

Position the brake caliper on the brake disc.

Position the rear wheel on the bearing surfaces in the swingarm.

700314-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

142

–

Push the rear wheel forward as far as possible and place the chain on the rear sprocket.

–

Pull the rear wheel back and push in the wheel spindle.

700315-01

–

Lay the chain adjuster  on the tensioning screw.

Position the chain adjuster  and place it on the tensioning screw.

Tighten nut .

Guideline

In order for the rear wheel to be correctly aligned, the markings on the left and right

chain adjusters must be in the same position relative to the reference marks .

Nut, rear wheel spindle

M25x1.5

90 Nm

Thread greased

(66.4 lbf ft)

700316-01

–

Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and

there is a tight spot.

–

Take the rear of the motorcycle off the work stand. ( S. 96)

Check the chain tension. ( S. 123)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

143

.47

hecking rear hub shock absorbers

Info

The engine power is transmitted by the rear sprocket to the rear wheel through 5 shock absorbers. They are subject to wear during

operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.

–

Remove the rear wheel.

S. 138)

–

Remove the rear sprocket carrier.

Check the rear hub for damage and wear.

If the rear hub shock absorbers are damaged or worn:

–

Change the shock absorber.

–

Position the rear sprocket carrier.

Info

A set of bolts and shock absorbers with as little free play as possible increases

the service life of the shock absorbers.

700274-01

Fitting the rear wheel.

S. 140)

.48

ire condition checking

Warning

Danger of accidentsꢀUncontrollable handling behavior caused by a flat tire.

For your own safety, have damaged tires changed immediately.

–

Warning

Danger of crashingꢀImpairment of riding behavior due to different tire tread patterns on front and rear wheels.

–

The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

144

Warning

Danger of accidentsꢀUncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels.

–

Only tires/wheels approved by KTM and with the corresponding speed index should be used.

Warning

Danger of accidentsꢀReduced road grip with new tires.

–

New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in

the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle

has been run in.

Info

The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

–

Check the front and rear tire for cuts, penetrations and other damage.

If the tires exhibit cuts, penetrations or other damage:

Change the tires.

–

Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth

If the minimum tread depth is insufficient:

Change the tires.

≥ 2 mm (≥ 0.08 in)

700267-01

–

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MAINTENANCE WORK ON CHASSIS AND ENGINE

145

.49

hecking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.

Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

–

Remove dust cap.

Check tire air pressure when tires are cold.

Tire air pressure, Solo

front

rear

2.5 bar (36 psi)

Tire air pressure with passenger / full payload

front

rear

2.5 bar (36 psi)

2.9 bar (42 psi)

700268-01

If the tire pressure does not meet specifications:

Correct tire pressure.

–

Mount dust cap.

Info

The rubber seal in the dust cap prevents air leaking out of the tire if the valve is

defective.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

146

.50

–

Insert the ignition key in the seat lock  and turn it anticlockwise.

Raise the rear of the seat, push it towards the rear, and remove it upwards.

700245-01

.51

–

Position the recesses of the seat to the lugs on the frame, lower the rear end and simul-

taneously push it forward.

–

Lock the seat by turning the ignition key in the seat lock.

Remove the ignition key from the seat lock.

Finally, check that the seat is correctly mounted.

700269-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

147

.52

–

Remove the seat. ( S. 146)

Operate lever .

Take off the passenger seat  toward the top.

700246-01

.53

–

Position the passenger seat in the space provided.

Press down the passenger seat until it clicks into place.

Finally, check that the passenger seat is correctly mounted.

700275-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

148

.54

–

Remove the seat. ( S. 146)

Position the steel cable from the toolset with one loop on the lug .

Steel cable (60012015000)

–

Guide the steel cable through the helmet opening.

Then position the free loop of the steel cable on the lug.

Position the helmet carefully on the side of the motorcycle.

Fit the seat. ( S. 146)

700336-01

.55

emoving the battery

Warning

Risk of injuryꢀBattery acid and battery gases cause serious cauterization.

–

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15

minutes and contact a doctor.

–

Switch off all power-consuming components and switch off the engine.

Remove the seat. ( S. 146)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

149

–

Disconnect the negative (minus) cable  of the battery.

700276-10

700277-10

700278-01

–

Remove the plus pole cover.

Disconnect the positive (plus)  cable of the battery.

–

Remove screws .

Removing the securing bracket .

Pull the battery upwards out of the battery rack.

Info

Never operate the motorcycle with a discharged battery or without a battery. In

both cases, electrical components and safety equipment can be damaged. The

vehicle is then no longer safe to ride.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

150

.56

nstalling the battery

–

Position the battery in the battery rack.

Info

The poles of the battery must face the rear of the vehicle.

–

Position the bracket .

700279-01

–

Mount and tighten screws .

Guideline

Remaining chassis screws

10 Nm (7.4 lbf ft)

–

Reconnect the positive (plus)  cable of the battery.

Position positive terminal cover.

700277-11

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MAINTENANCE WORK ON CHASSIS AND ENGINE

151

–

Reconnect the negative (minus) cable  of the battery.

–

Fit the seat. ( S. 146)

700276-11

.57

echarging the battery

Warning

Risk of injuryꢀBattery acid and battery gases cause serious cauterization.

–

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15

minutes and contact a doctor.

Warning

Environmental hazardꢀComponents and battery acid are a danger to the environment.

–

Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

152

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.

The charge state and the type of charge are very important for the service life of the battery.

Fast recharging with a high charge current shortens the battery's service life.

If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The

battery capacity is then reduced.

If the battery becomes discharged from starting, it must be recharged immediately.

If the battery rests for an extended time in a discharged state, it becomes over-discharged and sulfated, which will result in its

destruction.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

–

Switch off all power-consuming components and switch off the engine.

Remove the seat. ( S. 146)

Disconnect the negative (minus) cable of the battery to prevent damage to the vehicle's

electronics.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

153

–

Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the bat-

tery, and to test the generator. With this device, you cannot overcharge the battery.

Info

Never remove the lid .

Charge the battery according to the instructions  on the battery casing.

–

After charging the battery, switch off the battery charger. Reconnect the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the

motorcycle is not in use.

3 months

Fit the seat. ( S. 146)

100151-10

.58

hanging the main fuse

Warning

Fire hazardꢀThe electrical system can be overloaded by the use of incorrect fuses.

Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

–

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MAINTENANCE WORK ON CHASSIS AND ENGINE

154

Info

The main fuse protects all power-consuming components of the vehicle. The main fuse is under the seat.

–

Switch off all power-consuming components and switch off the engine.

Remove the seat. ( S. 146)

Remove protection covers .

Remove a defective main fuse  with a needle nose plier.

Info

A reserve fuse  is located in the starter relay.

–

Fit a new main fuse.

Fuse (58011109130) ( S. 213)

Info

If the new fuse burns out, contact an authorized KTM-RC8 workshop.

–

Attach the protection covers .

Fit the seat. ( S. 146)

700280-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

155

.59

hanging fuses of individual power consumers

Info

The fuse box containing the fuses of individual power consumers is located under the seat.

–

Switch off all power-consuming components and switch off the engine.

Remove the seat. ( S. 146)

Open the fuse box cover .

700281-01

–

Check the fuses.

Info

A defective fuse is shown by a burned-out fuse wire .

700282-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

156

–

Remove defective fuse.

Guideline

Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system

(optional)

Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp

Fuse 3 - 10A - horn, brake light

Fuse 4 - 10A - radiator fan

Fuse 5 - 10A - fuel pump

Fuse 6 - 10A - ignition / fuel injection

Fuse 7 - not used

Fuse 8 - 10A - for supplementary equipment (standard accessories)

Fuse 9 - 10A - for supplementary equipment (accessories connected with ignition

switch)

Fuse 10 - not used

Fuse SPARE - 10A/15A - spare fuses

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MAINTENANCE WORK ON CHASSIS AND ENGINE

157

Warning

Fire hazardꢀThe electrical system can be overloaded by the use of incorrect

fuses.

–

Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

–

Use spare fuses with the correct rating only.

Fuse (75011088010) ( S. 213)

Fuse (75011088015) ( S. 213)

Info

If the new fuse burns out, contact an authorized KTM-RC8 workshop.

Tip

Replace the spare fuse in the fuse box so that it is available if needed.

–

Close the fuse box cover.

Fit the seat. ( S. 146)

.60

Note

Damage to reflectorꢀKeep the glass of the bulb free of grease.

–

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the

reflector.

–

Switch off all power-consuming components and switch off the engine.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

158

–

Fold up the combination instrument. Pull the lug  out of the rubber holder .

–

Remove the rubber holder.

700293-01

700294-01

700295-01

–

Release the latch .

Remove the lamp cover .

–

Disconnect plug-in connector .

Push off the retaining clamp  on both sides, squeeze and fold to the side.

Remove headlight bulb .

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MAINTENANCE WORK ON CHASSIS AND ENGINE

159

–

Position the new headlight bulb in the headlight housing.

Low beam / high beam (H7) ( S. 213)

Info

Insert the headlight bulb so that the lug  is positioned in the cut-out.

–

Position the retaining clamp.

Position the plug-in connector.

700296-01

–

Position the lug  of the lamp cover in the notch. Engage the latch .

Check lighting function.

400422-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

160

–

Position the rubber holder .

–

Fold down the combination instrument. Position the lug  in the rubber holder.

700293-11

.61

Note

Damage to reflectorꢀKeep the glass of the bulb free of grease.

–

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the

reflector.

–

Switch off all power-consuming components and switch off the engine.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

161

–

Remove screws . Remove cover.

700297-01

–

Release the latch .

Remove the lamp cover .

700298-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

162

–

Disconnect plug-in connector .

Push off the retaining clamp  on both sides, squeeze and fold to the side.

Remove headlight bulb.

Position the new headlight bulb in the headlight housing.

Low beam / high beam (H7) ( S. 213)

Info

Insert the headlight bulb so that the lug is positioned in the cut-out.

700299-01

–

Position the retaining clamp.

Position the plug-in connector.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

163

–

Position the lug  of the lamp cover in the notch. Engage the latch.

–

Check lighting function.

400422-11

–

Position cover.

Info

Check for correct positioning and freedom of movement of the brake lines.

Mount and tighten screws .

Guideline

Remaining chassis screws

10 Nm (7.4 lbf ft)

700335-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

164

.62

Note

Damage to reflectorꢀKeep the glass of the bulb free of grease.

–

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the

reflector.

–

Switch off all power-consuming components and switch off the engine.

Remove screws . Remove cover.

700297-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

165

–

Release the latch .

–

Remove the lamp cover .

700298-01

–

Pull the parking light  carefully out of the holder.

Remove the light bulb.

Position a new light bulb in the holder.

Parking light (W2,1x9,5d) ( S. 213)

–

Carefully position the holder with the bulb in the holder in the headlight.

700300-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

166

–

Position the lug  of the lamp cover in the notch. Engage the latch.

–

Check lighting function.

400422-12

–

Position cover.

Info

Check for correct positioning and freedom of movement of the brake lines.

Mount and tighten screws .

Guideline

Remaining chassis screws

10 Nm (7.4 lbf ft)

700335-11

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MAINTENANCE WORK ON CHASSIS AND ENGINE

167

.63

–

On a light-colored wall behind a horizontal area, make a mark as high as the center of

the low beam headlight.

Make another mark at a distance of  under the first mark.

Guideline

Distance 

5 cm (2 in)

–

Stand the motorcycle at distance  in from of the wall and switch on the ignition and

the low beam.

Guideline

400420-10

Distance 

5 m (16 ft)

Check the headlight adjustment.

The border between light and dark must be exactly at mark  when the motorcycle is

operational and complete with rider.

If the boundary between light and dark does not meet specifications:

–

Adjust the headlamp range. ( S. 167)

.64

–

Check the headlight adjustment. ( S. 167)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

168

–

Adjust the beam distance of the headlight by turning screw .

Guideline

The boundary between light and dark must be exactly on the lower mark for a motor-

cycle with a rider (mark is applied under: Checking headlight adjustment).

Info

Turn clockwise to increase the light range, turn counterclockwise to reduce the

light range.

If you have a payload, you may have to correct the headlight range.

700285-01

.65

ctivating/deactivating ignition key

Info

The orange programming key must only be used for activating and deactivating!

If a black ignition key is lost or replaced, the black ignition keys must be activated/deactivated using the orange programming key.

You can activate or deactivate up to four black ignition keys. Only the black ignition keys trained during an activation procedure are

valid. All black ignition keys not trained in the activation procedure are invalid, but can be retrained in a further activation proce-

dure.

Loss of a black ignition key (second black ignition key available):

–

Press the emergency OFF switch into the position

Insert the orange programming key in the ignition lock.

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

lights up.

The immobilizer indicator lamp

–

Switch off the ignition by turning the orange programming key to the position

Pull out the orange programming key.

700234-10

Insert the black ignition key in the ignition lock.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

169

–

Switch on the ignition by turning the black ignition key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp

on again.

lights up, switches off briefly, and switches

–

Switch off the ignition by turning the black ignition key to the position

Remove the black ignition key.

Insert the orange programming key in the ignition lock.

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp

lights up, switches off briefly, and flashes

according to the number of functioning black ignition keys including the orange

programming key. In this case, twice.

–

Switch off the ignition by turning the orange programming key to the position

Pull out the orange programming key.

The lost black ignition key is deactivated.

The existing black ignition key is reactivated.

Loss of both black ignition keys (no black ignition key available):

–

Press the emergency OFF switch into the position

Insert the orange programming key in the ignition lock.

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

The immobilizer indicator lamp

Switch off the ignition by turning the orange programming key to the position

(MIL) lights up, switches off, and then starts to flash.

lights up.

–

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MAINTENANCE WORK ON CHASSIS AND ENGINE

170

–

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp

lights up, switches off briefly, and flashes

according to the number of functioning black ignition keys including the orange

programming key. In this case once, since all black ignition keys are deacti-

vated.

–

Switch off the ignition by turning the orange programming key to the position

Pull out the orange programming key.

All black ignition keys are deactivated.

–

Order a new black ignition key according to the key number on the KEYCODECARD

and activate it.

Activating ignition key:

–

Press the emergency OFF switch into the position

Insert the orange programming key in the ignition lock.

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

lights up.

The immobilizer indicator lamp

–

Switch off the ignition by turning the orange programming key to the position

Pull out the orange programming key.

Insert the black ignition key in the ignition lock.

Switch on the ignition by turning the black ignition key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp

on again.

lights up, switches off briefly, and switches

–

Switch off the ignition by turning the black ignition key to the position

Remove the black ignition key.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

171

–

To activate further ignition keys, repeat the last 4 steps with the respective ignition

key.

–

Insert the orange programming key in the ignition lock.

Switch on the ignition by turning the orange programming key to the position

EFI warning lamp

(MIL) lights up, switches off, and then starts to flash.

The immobilizer indicator lamp

lights up, switches off briefly, and flashes

according to the number of functioning black ignition keys including the orange

programming key.

–

Switch off the ignition by turning the orange programming key to the position

Pull out the orange programming key.

All black ignition keys are activated included in this job sequence are activated.

.66

The water pump with a 3D water pump wheel  in the engine ensures forced circulation of

the coolant. The heat exchanger enables faster warming of the engine oil at the start of a

journey and better heat dissipation for the engine oil during the journey.

The pressure in the cooling system resulting from heat is regulated by a valve in the radi-

ator cap . The heat expansion causes the surplus coolant to flow into the compensating

tank . When the temperature falls, this surplus coolant is sucked back into the cooling

system.

400415-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

172

Cooling takes place by means of the air stream and a radiator fan , which is controlled by

a thermoswitch.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling

effect.

400416-10

.67

hecking the coolant level

Warning

Danger of scaldingꢀThe coolant gets very hot when the motorcycle is driven and is under high pressure.

–

Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool-

ing system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Condition

Engine is cold.

–

Stand the motorcycle upright on a horizontal surface.

700324-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

173

–

Check the coolant level in the compensating tank.

The coolant level must be between MIN and MAX.

If there is no coolant in the compensating tank:

–

Check the cooling system for leaks.

Info

Do not operate the motorcycle!

If the coolant level in the compensating tank does not meet specifications, but

the tank is not empty:

–

Fill the cooling system compensating tank. ( S. 173)

.68

illing the cooling system compensating tank

Warning

Danger of scaldingꢀThe coolant gets very hot when the motorcycle is driven and is under high pressure.

–

Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool-

ing system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningꢀCoolants are poisonous and a health hazard.

–

Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.

Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

174

Note

Engine damageꢀAfter draining coolant and refilling the cooling system, the motorcycle must be raised at the front according to the model

type. This is the only way of ensuring that the cooling system is filled without air bubbles. Air in the cooling system can lead to engine fail-

ure.

–

Have the coolant changed by an authorized KTM-RC8 workshop.

–

Check the coolant level. ( S. 172)

Remove the cap  of the compensating tank.

Top up with coolant until the specified coolant level is reached.

Guideline

The coolant level must be between MIN and MAX.

Alternative 1

Coolant ( S. 221)

700324-01

Alternative 2

Coolant (mixed ready to use) ( S. 221)

–

Mount the cap of the compensating tank.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

175

.69

djusting basic position of clutch lever

–

Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

Info

Turn the adjusting screw clockwise to increase the distance between the clutch

lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the

clutch lever and the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any force.

Do not make any adjustments while riding!

700283-01

.70

hecking fluid level of hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

–

Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

176

–

Check the fluid level.

The fluid level must be between the MIN and MAX markings.

If the fluid level does not meet specifications:

Correct the fluid level of the hydraulic clutch. ( S. 176)

–

700350-01

.71

orrecting fluid level of hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

–

Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

Remove screw cover with membrane.

Correct the fuel level.

Guideline

The fluid level must be between the MIN and MAX markings.

Hydraulic fluid (15) ( S. 223)

Refit screw with membrane.

–

700284-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

177

.72

djusting gas Bowden cable

–

Move the handlebar to the straight-ahead position.

With the diagnostics tool KTM DIA, place the control motor for the throttle valve position

into the neutral position.

–

Loosen the counter nut .

Adjust the gas Bowden cable with the adjusting screw .

Guideline

Play in gas Bowden cable

3… 5 mm (0.12… 0.2 in)

–

Tighten the counter nut .

700317-01

.73

By removing or inserting the spacing sleeves , you can set the handlebar height at two

different positions.

Long distance sleeve 

15 mm (0.59 in)

With distance sleeves, the handlebar stub is positioned low for sports use. Removing the

distance sleeves gives a more upright sitting position.

Standard

Low position with distance sleeve

700319-12

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MAINTENANCE WORK ON CHASSIS AND ENGINE

178

.74

djusting handlebar height

Info

The handlebar stub position must be identical on the left and the right of the vehicle.

–

Loosen screw .

Info

Loosen the screw several turns to prevent damaging the fork lacquer when mov-

ing the handlebar stub.

–

Remove screw .

700318-01

–

Remove the spacer .

All cables routed under the upper triple clamp must now be routed under the handlebar

stub.

–

Push the handlebar stub carefully up to the upper triple clamp.

Mount and tighten screw.

Guideline

Remaining chassis screws

5 Nm (3.7 lbf ft)

700319-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

179

–

Tighten the screw.

Guideline

Screw, handlebar stub

20 Nm (14.8 lbf ft)

–

Repeat the adjustments on the other handlebar stub.

Move the handlebar to and fro over the entire steering range.

If the cables restrict the freedom of movement of the steering:

Correct the cable routing.

–

When fitting the spacers, carry out these steps in the same way.

700320-01

Info

The cables must then be positioned between the upper triple clamp and the

handlebar stub.

.75

The frame rear height can be set to two different positions, enabling ergonomic adjustment

of the seat height.

Seat height  (standard)

805 mm (31.69 in)

825 mm (32.48 in)

Seat height 

400439-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

180

.76

djusting rear frame position

Warning

Danger of accidentsꢀModifications to the chassis can seriously alter the vehicle's handling characteristics.

–

Following modifications, ride slowly at first to get the feel of the new handling characteristics.

Setting a higher seat position:

–

Remove screw  with washer on the left and right side of the vehicle.

–

Press the rear end down until the drill holes of the frame are level with the lower

front drill holes of the frame rear.

700327-10

–

Fit the screw and washer on the left and right sides of the vehicle, but do not

tighten.

700329-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

181

–

Remove screw  with washer on the left and right side of the vehicle.

–

Press the rear end up until the drill holes of the frame are level with the lower rear

drill holes of the frame rear.

–

Fit the screw and washer on the left and right sides of the vehicle, and tighten.

Guideline

Screw, subframe

25 Nm

Loctite^®243™

(18.4 lbf ft)

700327-11

–

Tighten the screw  on the left and right sides of the vehicle.

Guideline

Screw, subframe

25 Nm

Loctite^®243™

(18.4 lbf ft)

700330-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

182

–

When you screw in the rear left fixing screw, the plug-in cable binder  is pushed

out of the thread. To reposition the cable of the lambda probe, fix the plug-in cable

binder in the remaining free drill hole.

Info

Check the cable routing. The cable of the lambda probe must not be taut.

700338-01

Setting a lower seat position:

–

Remove screw  with washer on the left and right side of the vehicle.

–

Press the rear end down until the drill holes of the frame are level with the upper

rear drill holes of the frame rear.

–

Fit the screw and washer on the left and right sides of the vehicle, but do not

tighten.

700327-12

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MAINTENANCE WORK ON CHASSIS AND ENGINE

183

–

Remove screw  with washer on the left and right side of the vehicle.

–

Press the rear end up until the drill holes of the frame are level with the upper front

drill holes of the frame rear.

700327-14

700329-01

700327-13

–

Fit the screw and washer on the left and right sides of the vehicle, and tighten.

Guideline

Screw, subframe

25 Nm

Loctite^®243™

(18.4 lbf ft)

–

Tighten the screw  on the left and right sides of the vehicle.

Guideline

Screw, subframe

25 Nm

Loctite^®243™

(18.4 lbf ft)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

184

–

When you screw in the rear left fixing screw, the plug-in cable binder  is pushed

out of the thread. To reposition the cable of the lambda probe, fix the plug-in cable

binder in the remaining free drill hole.

Info

Check the cable routing. The cable of the lambda probe must not be taut.

700338-11

.77

hecking engine oil level

Info

The engine oil level must be checked at normal engine operating temperature.

–

Stand the motorcycle upright on a horizontal surface.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

185

–

Remove oil dipstick . Check the engine oil level in the measurement range.

Info

After switching off the engine, wait one minute before checking the level.

The engine oil level must be in the middle  of the measurement range of the oil

dipstick.

If the enigne oil level is outside the specified range:

–

Top up the engine oil. ( S. 192)

700301-10

–

Replace the oil dipstick.

.78

hanging engine oil and filter, cleaning oil screen

–

Drain the engine oil and clean the oil screens.

Fill up with engine oil. S. 190)

–

700349-01

.79

raining engine oil, cleaning oil screens

Warning

Danger of scaldingꢀEngine oil and gear oil get very hot when the motocycle is driven.

–

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

186

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Drain the engine oil only when the engine is warm.

–

Remove screws .

Take off the left exhaust cover .

700302-10

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MAINTENANCE WORK ON CHASSIS AND ENGINE

187

–

Stand the motorcycle on its side stand on a horizontal surface.

Place a suitable container under the engine.

Remove the oil drain plug  with the magnet, O-rings and oil screen.

Remove the oil filter.

S. 188)

Completely drain the engine oil.

700287-01

700292-01

700288-01

–

Thoroughly clean the magnet  and oil screen  of the oil drain plug.

–

Fit and tighten the oil drain plug with the magnet, O-rings and oil screen.

Guideline

Oil drain plug

M20x1.5

20 Nm (14.8 lbf ft)

Fit the oil filter.

S. 190)

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MAINTENANCE WORK ON CHASSIS AND ENGINE

188

–

Position the left exhaust cover .

Mount and tighten screws .

Guideline

–

Remaining chassis screws

5 Nm (3.7 lbf ft)

700302-10

.80

emoving oil filter

Warning

Danger of scaldingꢀEngine oil and gear oil get very hot when the motocycle is driven.

–

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

189

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

–

Place a suitable container under the engine.

Remove screws . Remove the oil filter cover  with the O-ring.

700289-01

–

Pull the oil filter element  out of the oil filter case.

Circlip pliers reverse (51012011000)

–

Completely drain the engine oil.

Clean the parts and the sealing area thoroughly.

700290-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

190

.81

itting oil filter

–

Insert the oil filter .

Lubricate the O-ring of the oil filter cover. Fit the oil filter cover .

Mount and tighten screws.

Guideline

Remaining engine screws

6 Nm (4.4 lbf ft)

700291-01

.82

illing up with engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

–

The oil must be topped up in two steps.

Engine oil 3.60 l (3.8 qt.)

External

Engine oil

temperature:

≥ 0 °C (≥ 32 °F)

(SAE 10W/50)

External

Engine oil

temperature:

< 0 °C (< 32 °F)

(SAE 5W/40)

700301-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

191

–

Remove the dipstick  and top up the engine oil.

Engine oil (1st

quantity)

3.00 l (3.17 qt.)

External

temperature:

≥ 0 °C (≥ 32 °F)

Engine oil

(SAE 10W/50)

External

Engine oil

temperature:

< 0 °C (< 32 °F)

(SAE 5W/40)

–

Replace the oil dipstick .

Danger

Danger of poisoningꢀExhaust gases are poisonous and can result in

unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventilation,

and do not start or run the engine in a closed space.

–

Start the engine and check that it is oil-tight.

Remove the dipstick  and pour in the remaining engine oil.

Engine oil (2nd

quantity)

0.60 l (0.63 qt.)

External

temperature:

≥ 0 °C (≥ 32 °F)

Engine oil

(SAE 10W/50)

External

Engine oil

temperature:

< 0 °C (< 32 °F)

(SAE 5W/40)

–

Replace the oil dipstick .

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MAINTENANCE WORK ON CHASSIS AND ENGINE

192

Danger

Danger of poisoningꢀExhaust gases are poisonous and can result in

unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventilation,

and do not start or run the engine in a closed space.

–

Start the engine and check that it is oil-tight.

Check the engine oil level. ( S. 184)

.83

opping up engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

–

Check the engine oil level. ( S. 184)

Engine oil (SAE 10W/50) ( S. 222)

700301-01

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MAINTENANCE WORK ON CHASSIS AND ENGINE

193

–

Remove the dipstick  and top up the engine oil.

Condition

External temperature: ≥ 0 °C (≥ 32 °F)

Engine oil (SAE 10W/50) ( S. 222)

Condition

External temperature: < 0 °C (< 32 °F)

Engine oil (SAE 5W/40) ( S. 222)

Info

For optimal performance of the engine oil, do not mix different types of engine

oil.

If appropriate, change the engine oil.

–

Replace the oil dipstick .

Danger

Danger of poisoningꢀExhaust gases are poisonous and can result in

unconsciousness and/or death.

–

When running the engine, always make sure there is sufficient ventilation,

and do not start or run the engine in a closed space.

–

Start the engine and check that it is oil-tight.

Check the engine oil level. ( S. 184)

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TROUBLESHOOTING

194

1T0ROUBLESHOOTING

Faults

Possible cause

Action

Engine doesn't crank when the electric

starter button is pressed

Operating error

–

Carry out the steps for starting.

S. 82)

Battery discharged

–

Recharge the battery.

S. 151)

Check closed-circuit current.

Fuse 1, or 6 blown

Change the fuses of individual power

consumers. ( S. 155)

Main fuse blown

–

Change the main fuse. ( S. 153)

Ignition/steering lock or emergency OFF

switch defective

Check the ignition/steering lock.

Check the safety start system.

Read flash code of immobilizer.

Activate the EFI control unit.

Check the CAN-Bus communication.

^{Check the emergency OFF swit}x^ch.

Safety start system defective

Immobilizer active

EFI control unit not activated

Malfunction of CAN-Bus communication

Combination instrument defective

A gear is engaged

Check the combination instrument.

Engine cranks only if the clutch lever is

pulled

Shift into neutral.

Safety start system defective

Fuse 5 blown

^{Check the safety start system.}x

Engine cranks although it is in gear

Engine cranks but doesn't start

Check the safety start system.

Change the fuses of individual power

consumers. ( S. 155)

Coupling of fuel hose connection not joined

together

–

Join coupling of fuel hose connection

together.

Plug connector of wiring harness oxidized

Clean plug connector and treat with con-

tact spray.

Fault in fuel injection system

Read the fault memory with KTM DIA.

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TROUBLESHOOTING

195

Faults

Possible cause

Action

Engine cranks but doesn't start

Fuel pump control defective

Fuel quality insufficient

Air filter very dirty

–

Check fuel pump control.

Add suitable fuel.

–

Engine has too little power

Chang the fuel filter.

Read the fault memory with KTM DIA.

^{Change the air filter.}x

Fuel filter very dirty

Fault in fuel injection system

Too little coolant in cooling system

Engine overheats HIGH TEMP

Check the cooling system for leaks.

Check the coolant level. ( S. 172)

Clean cooling fins.

Cooling fins very dirty

Kinked or damaged radiator hose

Thermostat defective

Fuse 4 blown

Change the coolant hose.

Check the thermostat.

Change the fuses of individual power

consumers. ( S. 155)

Defect in radiator fan system

Air in cooling system

Fault in fuel injection system

Lack of fuel

–

Check the radiator fan system.

^{Fill up and aerate the cooling system.}x

EFI warning lamp (MIL) lights up / flashes

Read the fault memory with KTM DIA.

Engine dies during the journey

Fill up with fuel. ( S. 89)

Fuse 1, 5 or 6 blown

Change the fuses of individual power

consumers. ( S. 155)

High oil consumption

Engine oil level too high

–

Check the engine oil level. ( S. 184)

Engine oil too thin (viscosity)

Change the engine oil and filter, clean

the oil screen.

Headlight and parking light do not work

Fuse 2 blown

–

Change the fuses of individual power

consumers. ( S. 155)

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TROUBLESHOOTING

196

Faults

Possible cause

Action

Brake light and horn do not work

Fuse 3 blown

–

Change the fuses of individual power

consumers. ( S. 155)

Battery discharged

Ignition not switched off when vehicle

parked

–

Recharge the battery.

S. 151)

Battery is not charged by the generator

–

Check charging voltage.

Combination instrument shows nothing in

display

Fuse 1 blown

Change the fuses of individual power

consumers. ( S. 155)

Speedometer in combination instrument

doesn't work

Wiring harness of wheel reveolution

counter damaged or plug-in connector

oxidized

–

Check the wheel speed sensor.

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IMMOBILIZER FLASH CODE

197

1IM1MOBILIZER FLASH CODE

Fault

Description

Possible cause

Action

Immobilizer indicator lamp

flashes 1x short, 1 second

pause, 2x short

All ignition keys inactive

–

Activate/deactivate the igni-

tion key. ( S. 168)

Immobilizer indicator lamp

flashes 1x short, 1 second

pause, 3x short

Malfunction, antenna of immo-

bilizer control unit

immobilizer control unit.

^{Check the antenna of the}x

Immobilizer indicator lamp

flashes 1x short, 1 second

pause, 4x short

Malfunction in transponder of

black ignition key

Use spare black ignition

key.

–

Order new spare key.

Activate/deactivate the igni-

tion key. ( S. 168)

Immobilizer indicator lamp

flashes 1x short, 1 second

pause, 5x short

Black ignition key inactive

–

Activate/deactivate the igni-

tion key. ( S. 168)

Immobilizer indicator lamp

flashes 1x short, 1 second

pause, 6x short

Malfunction, encryption, immo-

bilizer control unit to black igni-

tion key

Use the black ignition key

belonging to the vehicle.

Immobilizer indicator lamp

flashes 2x short, 1 second

pause, 1x short

Immobilizer control unit not

activated

Activate the immobilizer

control unit.

Immobilizer indicator lamp

flashes 3x short, 1 second

pause, 1x short

Malfunction, encryption query

from EFI control unit to immo-

bilizer control unit

Activate the EFI control

unit.

Immobilizer indicator lamp

flashes 3x short, 1 second

pause, 2x short

Malfunction of CAN-Bus com-

munication

Check the CAN-Bus commu-

nication.

Immobilizer indicator lamp

flashes 6x short

E²PROM malfunction

Change the immobilizer

control unit.

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ENGINE CONTROL FLASH CODE

198

1E2NGINE CONTROL FLASH CODE

Fault

Description

Possible cause

Action

EFI Warning lamp (MIL) flashes

2x short

Malfunction in ignition pulse

generator circuit

–

generator.

Check circuit A of throttle

^{Check the}x^{ignition pulse}

EFI Warning lamp (MIL) flashes

6x short

Input signal of throttle valve

position generator circuit A too

low

–

valve position generator.

Input signal of throttle valve

position generator circuit A too

high

Check circuit A of throttle

valve position generator.

EFI Warning lamp (MIL) flashes

7x short

Input signal of throttle valve

position generator circuit B too

low

Check circuit B of throttle

valve position generator.

Input signal of throttle valve

position generator circuit B too

high

Check circuit B of throttle

valve position generator.

EFI Warning lamp (MIL) flashes

9x short

Input signal from pressure sen-

sor, induction manifold (cylin-

der 1) too low

Check pressure sensor,

induction manifold (cylin-

der 1).

Input signal from pressure sen-

sor, induction manifold (cylin-

der 1) too high

Check pressure sensor,

induction manifold (cylin-

der 1).

EFI Warning lamp (MIL) flashes

1x long, 1x short

Input signal from pressure sen-

sor, induction manifold (cylin-

der 2) too low

Check pressure sensor,

induction manifold (cylin-

der 2).

Input signal from pressure sen-

sor, induction manifold (cylin-

der 2) too high

Check pressure sensor,

induction manifold (cylin-

der 2).

Check the intake air temper-

ature sensor.

EFI Warning lamp (MIL) flashes

1x long, 3x short

Input signal from intake air

temperatur sensor too low

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ENGINE CONTROL FLASH CODE

199

Fault

Description

Possible cause

Action

Check the intake air temper-

ature sensor.

Check pressure sensor,

ambient air.

Check pressure sensor,

ambient air.

Check the roll angle sen-

sor.

Check the roll angle sen-

sor.

EFI Warning lamp (MIL) flashes

1x long, 3x short

Input signal from intake air

temperatur sensor too high

–

EFI Warning lamp (MIL) flashes

1x long, 4x short

Input signal of pressure sensor

ambient air too low

Input signal of pressure sensor

ambient air too high

EFI Warning lamp (MIL) flashes

1x long, 5x short

Input signal from roll angle sen-

sor too low

Input signal from roll angle sen-

sor too high

EFI Warning lamp (MIL) flashes

1x long, 7x short

Malfunction in lambda probe

circuit (cylinder 1)

der 1).

^{Check l}x^{ambda probe (cylin-}

EFI Warning lamp (MIL) flashes

1x long, 8x short

Malfunction in lambda probe

circuit (cylinder 2)

der 2).

Check voltage supply to EFI

control unit.

Check the sidestand

switch.

EFI Warning lamp (MIL) flashes

2x long, 4x short

Malfunction in voltage supply

circuit to EFI control unit

EFI Warning lamp (MIL) flashes

2x long, 5x short

Malfunction in sidestand switch

circuit

EFI Warning lamp (MIL) flashes

3x long, 3x short

Malfunction in injection valve

circuit (cylinder 1)

der 1).

^{Check i}x^{njection valve (cylin-}

EFI Warning lamp (MIL) flashes

3x long, 4x short

Malfunction in injection valve

circuit (cylinder 2)

der 2).

Check the ignition coil

(cylinder 1).

Check the ignition coil

(cylinder 2).

EFI Warning lamp (MIL) flashes

3x long, 7x short

Malfunction in ignition coil cir-

cuit (cylinder 1)

EFI Warning lamp (MIL) flashes

3x long, 8x short

Malfunction in ignition coil cir-

cuit (cylinder 2)

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ENGINE CONTROL FLASH CODE

200

Fault

Description

Possible cause

Action

EFI Warning lamp (MIL) flashes

4x long, 1x short

Interruption/short-circuit to

ground in fuel pump control

circuit

–

Check fuel pump

control.

Short-circuit to plus in fuel

pump control circuit

–

Check fuel pump

control.

EFI Warning lamp (MIL) flashes

4x long, 5x short

Malfunction or short circuit to

ground in lambda probe heating

circuit (cylinder 1)

probe (cylinder 1).

^{Check heating of la}x^mbda

Malfunction or short circuit to

plus in lambda probe heating

circuit (cylinder 1)

–

probe (cylinder 1).

^{Check heating of la}x^mbda

EFI Warning lamp (MIL) flashes

4x long, 6x short

Malfunction or short circuit to

ground in lambda probe heating

circuit (cylinder 2)

probe (cylinder 2).

Malfunction or short circuit to

plus in lambda probe heating

circuit (cylinder 2)

probe (cylinder 2).

EFI Warning lamp (MIL) flashes

4x long, 9x short

Malfunction in idling control

system circuit

–

Check idle speed

control.

EFI Warning lamp (MIL) flashes

5x long

Malfunction in throttle valve

stepper circuit, circuit B

stepper motor.

^{Check circuit B}x^{of throttle}

^Checkx^{the secondary air}

EFI Warning lamp (MIL) flashes

5x long, 4x short

Interruption/short-circuit to

ground in secondary air valve

circuit

valve.

Short-circuit to plus in sec-

ondary air valve circuit

–

valve.

Check idle speed

control.

^Checkx^{the secondary air}

EFI Warning lamp (MIL) flashes

6x long, 1x short

Malfunction in idling control

system basic setting

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ENGINE CONTROL FLASH CODE

201

Fault

Description

Possible cause

Action

EFI Warning lamp (MIL) flashes

6x long, 2x short

Malfunction in idling control

system

–

Check idle speed

control.

EFI Warning lamp (MIL) flashes

6x long, 8x short

Connection of pressure sensor,

induction manifold (cylinder 1)

leaky

–

Check pressure sensor,

induction manifold (cylin-

der 1).

EFI Warning lamp (MIL) flashes

6x long, 9x short

Connection of pressure sensor,

induction manifold (cylinder 2)

leaky

–

Check pressure sensor,

induction manifold (cylin-

der 2).

EFI Warning lamp (MIL) flashes

7x long, 2x short

Malfunction of throttle valve

stepper, circuit B

–

stepper motor.

Check the CAN-Bus commu-

nication.

^{Check circuit B}x^{of throttle}

EFI Warning lamp (MIL) flashes

9x long, 1x short

Malfunction of CAN-Bus com-

munication

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CLEANING

202

1C3LEANING

3.1

Note

Material damageꢀDamage and destruction of components by high-pressure cleaning equipment.

–

Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical

components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazardꢀProblem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

To maintain the value and appearance of the motorcycle over a long period, clean it regularly.

Avoid direct sunshine when cleaning the motorcycle.

–

Before cleaning, seal the exhaust system to prevent water from entering.

Remove loose dirt first with a soft jet of water.

Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.

Motorcycle cleaner ( S. 225)

Info

Use warm water mixed with a normal commercial engine cleaner and a soft sponge.

If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

–

After cleaning the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.

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CLEANING

203

Warning

Danger of accidentsꢀReduced braking due to wet or dirty brakes.

–

Clean or dry dirty or wet brakes by riding and braking gently.

–

After cleaning, ride a short distance until operating temperature is reached, and apply the brakes.

Info

The heat causes water to evaporate from inaccessible parts of the engine and brakes.

–

After the engine has cooled down, lubricate or grease all moving parts and bearings.

Clean the chain. ( S. 122)

Treat bare metal (except for brake discs and the exhaust system) with an anticorrosive.

Cleaning and polishing materials for metal, rubber and plastic ( S. 224)

Treat all painted parts with a mild lacquer care spray.

High-luster polish for paint ( S. 224)

–

Oil the ignition/steering lock, tank lock, and seat lock.

Universal oil spray ( S. 225)

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CONSERVATION FOR WINTER OPERATION

204

1C4ONSERVATION FOR WINTER OPERATION

4.1

onservation for winter operation

Info

If you use the motorcycle in the winter, you have to expect salt on the roads. You therefore have to take precautions against the

aggressive road salt.

If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

–

Clean the motorcycle. ( S. 202)

Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.

Info

Avoid getting anticorrosive on the brake discs: this would badly affect the braking.

After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.

–

Clean the chain. ( S. 122)

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STORAGE

205

1S5TORAGE

5.1

Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should

do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the

new season.

–

Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.

Clean the motorcycle. ( S. 202)

Change the engine oil and filter, clean the oil screen.

Check the coolant level. ( S. 172)

Check the antifreeze.

S. 145)

S. 148)

S. 151)

Remove the battery.

Recharge the battery.

Guideline

^{Checking the tire air}x^{pressure. (}

Storage temperature of battery without direct sunshine.

0… 35 °C (32… 95 °F)

–

The storage place should be dry and not subject to large temperature differences.

Info

KTM recommends jacking up the motorcycle.

–

Jack up the motorcycle rear end. ( S. 96)

Jack up the motorcycle at the front. ( S. 95)

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STORAGE

206

–

Cover the motorcycle with a porous sheet or blanket.

Info

Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during

combustion condenses and causes valves and exhaust system to rust.

5.2

utting into operation after storage

–

Take the front of the motorcycle off the work stand. ( S. 95)

S. 96)

Recharge the battery.

Install the battery.

^{Take the rear of the m}x^{otorcycle off the work stand. (}

Set the clock with SET CLOCK. ( S. 62)

Fill up with fuel. ( S. 89)

Make checks before putting into operation. ( S. 81)

Make a test ride.

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TECHNICAL DATA - ENGINE

207

1T6ECHNICAL DATA - ENGINE

Design

2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled

Displacement

Stroke

1,150 cm³ (70.18 cu in)

69 mm (2.72 in)

Bore

103 mm (4.06 in)

Compression ratio

Control

12,5:1

DOHC, 4 valves per cylinder, chain-driven

Valve - diameter

Intake

42 mm (1.65 in)

34 mm (1.34 in)

Exhaust

Valve clearance

Exhaust at: 20 °C (68 °F)

Intake at: 20 °C (68 °F)

Crankshaft bearing

Conrod bearing

Piston pin bearing

Piston

0.25… 0.30 mm (0.0098… 0.0118 in)

0.10… 0.15 mm (0.0039… 0.0059 in)

Sleeve bearing

No bearing bushes - DLC-coated piston pins

Forged light alloy

Piston ring

1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring

Pressure circulation lubrication with 3 rotor pumps

40:76

Engine lubrication

Primary transmission

Clutch

Multi-disc clutch in oilbath / hydraulically operated

6-speed claw gears

Transmission

Transmission ratio

1st gear

14:36

16:30

2nd gear

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TECHNICAL DATA - ENGINE

208

3rd gear

20:30

4th gear

21:27

5th gear

23:26

6th gear

25:26

Mixture preparation

Ignition system

Electronically controlled fuel injection

Contactless controlled fully electronic ignition with digital ignition

adjustment

Generator

12 V, 390 W

Spark plug

NGK LKAR9BI9

Electrode gap, spark plug

Cooling

0.8… 0.9 mm (0.031… 0.035 in)

Water cooling, permanent circulation of coolant by water pump

Electric starter

Cold start device

6.1

Engine oil

3.60 l (3.8 qt.)

External temperature: ≥ 0 °C

Engine oil (SAE 10W/50)

Engine oil (SAE 5W/40)

(≥ 32 °F)

External temperature: < 0 °C

(< 32 °F)