KTM 1190 RC8 manual

OWNER 'S MANU AL 2008 1190  RC8  EU 1190  RC8  AU S/UK 1190  RC8  FR 1190  RC8  JP ART. NO. 3211250e n[...]

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DEAR KTM CUS TOMER 1 DEAR KTM CUSTOMER Congratulations on yo ur decision to purchase a KT M motorcycle. You are no w the owner of a state-of-the- art sports motorcycle tha t will give you enormous ple asure if you service and mai ntain it accordingly. We wish you great pleasu re riding the vehicle! Please enter the serial nu mbers of your vehicle b[...]

DEAR KTM CUS TOMER 2 © 2008 by KTM-Sportm otorcycle AG, Mattighof en Austria All rights reserved Reproduction, even in p art, is permitted only with the e xpress written permiss ion of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the i nternational quality ma nagement standard ISO 9001, KTM uses qualit y assurance processes t h[...]

CONTENTS 3 CONTENTS MEANS OF REPRESEN TATION ............................ ................... 7 IMPORTANT NOTES ............................ ............................... .... 8 VIEW OF VEHICLE ............................ ............................... ..... 12 View of vehicle, front l eft side ............................................ 12 Vi[...]

CONTENTS 4 Setting number of laps SE T  NUM  LAPS ......................... ..... 66 Setting fuel reserve dis play TRIPF  RESET ........................... 67 Setting kilometers/m iles SET  KM/MILES............................. 68 Setting temperature u nit SET  °C/°F .............. ...................... 69 Switching external tem p[...]

CONTENTS 5 Adjusting shift lever ................................. ....................... 116 Adjusting the footbrak e pedal stub ........... ........................ 120 Adjusting the footbrak e pedal ........................... ............... 121 checking for chain dirt ...... .............................. ................ 121 Cleaning the cha[...]

CONTENTS 6 Fitting oil filter  x ......... .............................. ................... 190 Filling up with engine oil  x ............................. ............... 190 Topping up engine oil ....................................... .............. 192 TROUBLESHOOTIN G .......................................... ................ 194 IMMO[...]

MEANS OF RE PRESENTA TION 7 1 MEANS OF REPRESENTAT ION Symbols used The following explain s the meaning of specific sy mbols. Identifies an expecte d reaction (e.g. of an operatio n or a function). Identifies an unexpec ted reaction (e.g. of an opera tion or a function). All jobs marked with this sy mbol require specialis t knowledge and technic al[...]

IMPORTA NT NOTES 8 2 IMPORTANT NOTES Use definition KTM sport motorcycle s are designed and constr ucted to meet the normal de mands of regular road and ra ce track operation, but not fo r use on dirt roads. Info The motorcycle is auth orized for public road traffic i n the homologous versio n only. Maintenance A prerequisite for fault-f ree operat[...]

IMPORTA NT NOTES 9 You will find the current  KTM  PowerParts for your v ehicle on the KTM website . International KTM W ebsite: http://www.ktm .com Work rules During assembly, non -reusable parts (e.g. self -locking screws and nuts , seals and seal rings, O-ring s, pins, lock washers) mu st be replaced by new parts. If a thread lock (e.g. ?[...]

IMPORTA NT NOTES 10 notes/warnings Be sure to pay attention to th e notes and warnings given h ere. Info Various notes and warn ing stickers are attached to t he vehicle. Do not remove a ny notes and warning stick ers. If these are removed, you or other persons may n ot recognize potential da nger and therefore be liab le to injury. Grades of risks[...]

11[...]

VIEW OF VEHICL E 12 3 VIEW OF VEHICLE 3.1 View of vehicle, fron t left side 700243-10[...]

VIEW OF VEHICL E 13 1 Clutch lever 2 Light switch, headlig ht flasher switch, indic ator switch, horn button 3 Filler cap 4 Seat 5 Seat lock 6 Oil dipstick 7 Side stand 8 Shift lever 9 Passenger footrest s[...]

VIEW OF VEHICL E 14 3.2 View of vehicle, rear r ight side 700242-10[...]

VIEW OF VEHICL E 15 1 Passenger seat 2 Supporting strap 3 Rear mirror 4 Combination instrum ent 5 Emergency OFF switc h, electric starter button 6 Hand brake lever 7 Chassis number, type l abel 8 Rear brake caliper 9 Foot brake pedal 10 Engine number 11 Brake calipers, front[...]

LOCATION O F SERIAL NUM BERS 16 4 LOCATION OF SERIAL NU MBERS 4.1 Chassis number/ty pe label 700231-01 The chassis number   i s stamped on the frame beh ind the steering head on the rig ht. The type label   is on the fra me above the chassis num ber. 4.2 Key number 700222-01 The key number  Code  number   can be found on the[...]

LOCATION O F SERIAL NUM BERS 17 4.3 Engine number 700223-01 The engine number   is s tamped on the right side of the e ngine. 4.4 Fork part number 700224-01 The fork part number   is s tamped on the inner side of th e fork stub.[...]

LOCATION O F SERIAL NUM BERS 18 4.5 Shock absorber par t number 700225-01 The shock absorber pa rt number   is stamped on th e upper part of the shock abso rber above the adjusting rin g towards the rear. 4.6 Steering damper pa rt number 700226-01 The steering damper pa rt number   is stamped on t he top of the steering dampe r.[...]

OPERATIN G ELEMENTS 19 5 OPERATING ELEMENTS 5.1 Clutch lever 700227-01 The clutch lever   is fitte d on the left side of the handleba r. The clutch is hydraulic a nd self-adjusting. 5.2 Hand brake lever 700228-01 The handbrake lever   i s fitted on the right side of the han dlebar. The hand brake lever ope rates the front brake.[...]

OPERATIN G ELEMENTS 20 5.3 Light switch 700230-13 The light switch   is fitted o n the left side of the handleba r. Possible states Low beam on – Light switch i s turned downwards. In this p osition, the low beam and tail light are swit ched on. High beam on – Light switc h is turned upwards. In this po sition, the low beam, the hig[...]

OPERATIN G ELEMENTS 21 5.5 Flasher switch 700230-12 The flasher switch   is fit ted on the left side of the handle bar. Possible states Flasher light off Flasher light, left, on –  Flasher switch presse d to the right. The flasher switch returns automa tically to the central positi on after use. Flasher light, right, on – Flasher sw[...]

OPERATIN G ELEMENTS 22 5.7 Ignition/steering lo ck 700234-01 The ignition/steerin g lock   is located in front of the u pper triple clamp. Possible states Ignition off – In this posit ion, the ignition circuit is int errupted, a running engine stops, and a non- running engine will not star t. The black ignition key can be removed. Igniti[...]

OPERATIN G ELEMENTS 23 5.9 Electric starter button 700229-12 The electric starter butt on   is fitted on the right side of th e handlebar. Possible states • Electric starter button  in neutral position • Electric starter button  pressed – In this positi on, the electric starter is ope rated.[...]

OPERATIN G ELEMENTS 24 5.10 Combination instru ment - overview 400430-10 1 display ( S. 27) 2 Function buttons 3 Indicator lamps ( S. 29) 4 info display ( S. 28)[...]

OPERATIN G ELEMENTS 25 5.11 Combination instru ment - function button s on handlebar 600642-10 The  Mode  button   is fitted on the handlebar, fro nt left. The  Lap  button   is fit ted on the handlebar, rear le ft.[...]

OPERATIN G ELEMENTS 26 5.12 Combination instru ment - activation and tes t 400429-10 Activation The combination inst rument is activated when th e ignition is switched on. Test The segments of the tach ometer light up in and switch o ff in sequence. The speed display cou nts from 0 to 300 and back. The remaining displa y segments outside the inf o [...]

OPERATIN G ELEMENTS 27 5.13 display 400430-12 The tachometer   dis plays the engine speed in re volutions per minute (RP M). The red marking   mark s the over-rev (excessiv e speed) range of the engine . The speed   is displaye d in kilometers per hour  k m/h or in miles per hour  Mp h . The time appears in segm ent   [...]

OPERATIN G ELEMENTS 28 5.14 info display 400430-13 The info display   has two m enus. Menu 1 is ROAD  mode (st andard) for riding on public ro ads. Menu 2 is RACE  mode for rid ing on race courses. It allow s riders to time laps themse lves. If the  general warning lam p  lights up, the correspond ing message is shown per iodicall[...]

OPERATIN G ELEMENTS 29 5.15 Indicator lamps 400430-14 Possible states The flasher indicator la mp flashes green in same rh ythm as the flasher. – The flasher is switche d on. The oil indicator lamp lig hts up red – The oil pressure i s too low. The shift warning light sh ows/flashes red – The se t shift speed is reached. The idling s[...]

OPERATIN G ELEMENTS 30 5.16 Notes/warnings on t he combination instru ment 400476-01 LOW  FUEL appears on th e info display if the minimum range falls below the sp ecified value. Distance 25  km (15.5  mi) 400471-01 LOW  BATTERY appear s on the info display if the batte ry voltage falls below the sp ecified value. Battery voltage 10.80 [...]

OPERATIN G ELEMENTS 31 400472-01 SERVICE  IN  xxx  KM(M PH) appears on the info disp lay if the distance to the next s ervice falls below the specified va lue. Distance 500  km (310 .7  mi) 400474-01 HIGH  TEMP appears on t he info display if the coolant te mperature rises above t he specified value. Coolant temperatur e 120  ?[...]

OPERATIN G ELEMENTS 32 400470-01 REAR  SENSOR appear s on the info display if the coola nt temperature sensor of th e rear cyclinder is defective . 400468-01 SENSOR  ERROR appea rs on the info display if the cool ant temperature betwee n the coolant temperature sensor s of the front and rear cylinders d iffers by more than the spec ified valu[...]

OPERATIN G ELEMENTS 33 5.17 ODO menu 400438-01 Condition • The ignition is on. • ROAD  mode – Press the MODE  button b riefly and repeatedly un til ODO appears at the top left of th e info display. ODO shows the total distan ce covered. TripDist shows the dist ance covered since the las t reset. For example, betw een two refueling stops[...]

OPERATIN G ELEMENTS 34 5.18 FUELDISTANCE m enu 400441-01 Condition • The ignition is on. • ROAD  mode – Press the MODE  button b riefly and repeatedly un til FUELDISTANCE appe ars at the top of the info display. TripFuel shows the dis tance covered since the fu el reserve level was reach ed. Info This is displayed only af ter you reach [...]

OPERATIN G ELEMENTS 35 5.19 FUELRANGE menu 400477-01 Condition • The ignition is on. • ROAD  mode – Press the MODE  button b riefly and repeatedly un til FUELRANGE appears at th e top of the info display. TripFuel shows the dis tance covered since the fu el reserve level was reach ed. Info This is displayed only af ter you reach the fue[...]

OPERATIN G ELEMENTS 36 5.20 DISTANCE  TO Next  Service menu 400443-01 Condition • The ignition is on. • The motorcycle is stan ding. • ROAD  mode – Press the MODE  button b riefly and repeatedly un til DISTANCE  TO Next  Ser vice appears in the info display. DISTANCE  TO  Next  Se rvice shows the distance b efore [...]

OPERATIN G ELEMENTS 37 5.21 LAPSTOGO menu 400444-01 Condition • The ignition is on. • RACE  mode – Press the MODE  button b riefly and repeatedly un til LAPSTOGO appears at the t op left of the info display. LAPSTOGO shows the num ber of remaining laps. If an R appears after LAPSTO GO , the stopwatch is runni ng in the background. If a [...]

OPERATIN G ELEMENTS 38 5.22 TOPSPEED menu 400445-01 Condition • The ignition is on. • RACE  mode – Press the MODE  button b riefly and repeatedly un til TOPSPEED appears at th e top left of the info display. If an R appears after TOPSPE ED , the stopwatch is runni ng in the background. If a P appears after TOPSPEE D , the stopwatch is n[...]

OPERATIN G ELEMENTS 39 5.23 LAP/BESTLAP/L astLap menu 400446-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE  mode – Press the MODE  button b riefly and repeatedly un til LAP/BESTLAP/LastL ap appears in the info display. LAP shows the selected la p. BESTLAP shows the num ber of the lap with the best lap tim e.[...]

OPERATIN G ELEMENTS 40 5.24 LAP/BESTLAP/T opSpeed menu 400447-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE  mode – Press the MODE  button b riefly and repeatedly un til LAP/BESTLAP/TopS peed appears in the info display. LAP shows the selected la p. BESTLAP shows the lap in w hich the highest maximu m speed [...]

OPERATIN G ELEMENTS 41 5.25 Total distance menu i n Race  mode RACE ODO 400448-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE  mode – Press the MODE  button b riefly and repeatedly un til RACEODO appears at the to p of the info display. RACEODO shows the total d istance covered in RACE  mode. RaceTrip s[...]

OPERATIN G ELEMENTS 42 5.26 SET ‑ UP menu 400449-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. On the  CHANGE  MODE m enu, you can select betwe en  ROAD and  RACE  mo de. You can set the clock on the  SET  CLOCK menu. On the  SETTINGS m[...]

OPERATIN G ELEMENTS 43 5.27 CHANGE  MODE m enu 400475-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  or the button  briefly a nd repeatedly until the symbol  is o n CHANGE  MODE in the info d isplay. On the  CHANGE  MODE[...]

OPERATIN G ELEMENTS 44 5.28 SET  CLOCK menu 400455-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  once until the symbol  is on SET  CLOCK in the info disp lay. You can set the clock on the  SET  CLOCK menu. Press the button[...]

OPERATIN G ELEMENTS 45 5.29 SETTINGS menu 400456-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. On the  SHIFT  RPMS me nu, you can activate the shi ft warning light. On[...]

OPERATIN G ELEMENTS 46 5.30 SHIFT  RPMS men u 400460-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. – Press the MODE  button b riefly. On the  SHIFT  RPMS me nu[...]

OPERATIN G ELEMENTS 47 5.31 LAP menu,  LAP  BL ANK  T button 400461-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. – Press the button  once until the symbol [...]

OPERATIN G ELEMENTS 48 5.32 SET  NUM  LAPS me nu 400462-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. – Press the button  twice until the symbol  is on SET [...]

OPERATIN G ELEMENTS 49 5.33 TRIP  F  RESET men u 400463-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. – Press the button  three times un til the symbol  is on [...]

OPERATIN G ELEMENTS 50 5.34 UNITS menu 400458-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  three times un til the symbol  is on UNITS in the info dis play. On the  SET  KM/MILE S menu, you can set the units fo r measuring speed[...]

OPERATIN G ELEMENTS 51 5.35 SET  KM/MILES men u 400464-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  three times un til the symbol  is on UNITS in the info dis play. – Press the button  or the button  briefly a nd repeatedl[...]

OPERATIN G ELEMENTS 52 5.36 SET  °C/°F menu 400465-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  three times un til the symbol  is on UNITS in the info dis play. – Press the button  once until the symbol  is on SET  °[...]

OPERATIN G ELEMENTS 53 5.37 OPTIONS menu 400459-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  four times un til the symbol  is on OPTIONS in the inf o display. On the  OPTION  TPMS m enu, you can switch the tire p ressure check [...]

OPERATIN G ELEMENTS 54 5.38 TPMS menu 400478-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  four times un til the symbol  is on OPTIONS in the inf o display. – Press the MODE  button b riefly. On the  OPTION  TPMS m enu, you[...]

OPERATIN G ELEMENTS 55 5.39 OPTION  OUTERT EMP menu 400466-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button  and the button  for 3 - 5 seco nds. – Press the button  four times un til the symbol  is on OPTIONS in the inf o display. – Press the button  once until the symbol  is on OPT[...]

OPERATIN G ELEMENTS 56 Table of functions Display Press the button  . Press the button  . Press the button  and the button  for 3 - 5 seconds. Press the MODE  button for 3 - 5 seconds. Press the MODE  button briefly. FUELDISTANCE menu no function no function The display changes to the SET ‑ UP  menu no function Next display m[...]

OPERATIN G ELEMENTS 57 Table of functions Display Press the button  . Press the button  . Press the button  and the button  for 3 - 5 seconds. Press the MODE  button for 3 - 5 seconds. Press the MODE  button briefly. Total distance menu in Race  mode RACEODO no function no function The display changes to the SET ‑ UP  menu[...]

OPERATIN G ELEMENTS 58 Table of functions Display Press the button  . Press the button  . Press the button  and the button  for 3 - 5 seconds. Press the MODE  button for 3 - 5 seconds. Press the MODE  button briefly. TRIP  F  RESET menu increases th e value reduces the value no function Open and exit  TRIP  F  RESET[...]

OPERATIN G ELEMENTS 59 Table of conditions a nd activability Display • The igni- tion is on. • ROAD  mode • The igni- tion is on. • The motor- cycle is standing. • ROAD  mode • The igni- tion is on. • RACE  mode • The igni- tion is on. • The motor- cycle is standing. • RACE  mode • The igni- tion is on. • The mot[...]

OPERATIN G ELEMENTS 60 Table of conditions a nd activability Display • The igni- tion is on. • ROAD  mode • The igni- tion is on. • The motor- cycle is standing. • ROAD  mode • The igni- tion is on. • RACE  mode • The igni- tion is on. • The motor- cycle is standing. • RACE  mode • The igni- tion is on. • The mot[...]

OPERATIN G ELEMENTS 61 400446-01 – Press the MODE  button b riefly and repeatedly un til LAP/BESTLAP/LastL ap appears in the info display. LAP01 appears on the left of th e info display. – Press the button  . The next lap is displayed . – Press the button  . The previous lap is displ ayed. – Press the MODE  button b riefly. Next[...]

OPERATIN G ELEMENTS 62 5.42 Setting  ROAD or  RA CE  mode Condition The ignition is on. The motorcycle is stan ding. 400475-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  or the button  briefly a nd repeatedly until the symbol  is o n CHANGE  MODE in the info d isplay. – Press the MOD[...]

OPERATIN G ELEMENTS 63 400455-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  once until the symbol  is on SET  CLOCK in the info disp lay. – Press the MODE  button b riefly. The hour is shown. – Set the hour with the button or the  bu tton  . – Press the MODE  button b riefly. The[...]

OPERATIN G ELEMENTS 64 – Press the MODE  button b riefly. RPM1 and  RPM2 appe ar on the info display. The engine speed after  RPM1 flashes. Info The engine speed can be s et at intervals of 50. RPM1 is the engine speed a bove which the shift warnin g light starts to flash. – Set the engine speed with t he  button or the   butt[...]

OPERATIN G ELEMENTS 65 – Press the MODE  button b riefly. 5.45 Setting the blank time o f the LAP  button LAP  BLANK  T Condition The ignition is on. The motorcycle is stan ding. 400461-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis [...]

OPERATIN G ELEMENTS 66 – Press the button  briefly and rep eatedly until the symbol  is on EXIT  SETUP in the info display. – Press the MODE  button b riefly. 5.46 Setting number of laps S ET  NUM  LAPS Condition The ignition is on. The motorcycle is stan ding. 400462-01 – Press the button  and the button  for 3 - 5 se[...]

OPERATIN G ELEMENTS 67 – Press the MODE  button b riefly. 5.47 Setting fuel reserve di splay TRIPF  RES ET Condition The ignition is on. The motorcycle is stan ding. 400463-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  twice until the symbol  is on SETTINGS in the info dis play. – Press the[...]

OPERATIN G ELEMENTS 68 5.48 Setting kilometers/ miles SET  KM/MIL ES Info Making a country-spe cific setting. Condition The ignition is on. The motorcycle is stan ding. 400464-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  three times un til the symbol  is on UNITS in the info dis play. – Press t[...]

OPERATIN G ELEMENTS 69 5.49 Setting temperatu re unit SET  °C/°F Condition The ignition is on. The motorcycle is stan ding. 400465-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  three times un til the symbol  is on UNITS in the info dis play. – Press the button  once until the symbol  is [...]

OPERATIN G ELEMENTS 70 400466-01 – Press the button  and the button  for 3 - 5 seco nds. – Press the button  four times un til the symbol  is on OPTIONS in the inf o display. – Press the button  once until the symbol  is on OPTIONS  OUTTEMP i n the info dis- play. – Press the MODE  button b riefly. You see  ENABLE[...]

OPERATIN G ELEMENTS 71 5.51 Opening the filler cap 700235-01 – Lift the cover   of the filler c ap and insert the ignition key i n the lock. – Turn the ignition key cloc kwise until the filler cap ope ns. – Open the filler cap.[...]

OPERATIN G ELEMENTS 72 5.52 Closing the filler cap 700236-01 – Close the filler cap. Push d own the filler cap slightly unt il the lock closes. – Remove the ignition ke y and close the cover. 5.53 Supporting strap 700244-01 The supporting strap   is provided for the passen ger to hold on to.[...]

OPERATIN G ELEMENTS 73 5.54 Seat lock 700245-01 The seat lock   is behind th e seat. It can be locked with the igni tion key. 5.55 Tool set 700310-01 The tool set   is in the storag e compartment under the s eat.[...]

OPERATIN G ELEMENTS 74 5.56 Helmet lock 700337-01 The steel cable in the tool se t can be used to lock a helmet to th e vehicle to prevent it from being stolen. Warning Danger of accident s   Impairment of handlin g characteristics and ve hicle operation by a fitted helmet lock or hel met. – Do not use the helmet lock fo r holding a helmet or o[...]

OPERATIN G ELEMENTS 75 5.58 Shift lever 700239-01 The shift lever   is mount ed on the left of the engine. 700238-01 The gear positions can b e seen in the picture. The neutral or idle positio n  is between the first and sec ond gear.[...]

OPERATIN G ELEMENTS 76 5.59 Foot brake pedal 700237-01 The footbrake pedal   i s in front of the right footrest. The footbrake pedal op erates the rear brake. 5.60 Side stand 700258-01 The side stand   is coup led with the safety start syste m; see the riding instructi ons. Possible states • Side stand folded out – T he vehicle c[...]

TIPS ON PUTT ING INTO OPER ATION 77 6 TIPS ON PUTTING INTO OPE RATION 6.1 advice on first use Danger Danger of accident s   Danger from insuffici ent traffic competenc e. – Do not use the vehicle if you a re not fit to deal with traffic or if you ha ve consumed alcohol an d/or medicaments or dru gs. Warning Risk of injury   Risk of in jury by[...]

TIPS ON PUTT ING INTO OPER ATION 78 Info When using your vehic le, remember that others m ay feel disturbed by exces sive noise. – Make sure that the pre-de livery inspection work ha s been carried out exclus ively by an authorized KTM -RC8 workshop. You receive a delivery ce rtificate and the service re cord at vehicle handove r. – Before your[...]

TIPS ON PUTT ING INTO OPER ATION 79 – Avoid full-throttle ope ration! 6.3 Loading the vehicle Warning Danger of accident s   Unstable riding behav ior. – Do not exceed the maxim um permitted weight and a xle loads. The overall weig ht consists of: motorcyc le operational and with a full tank, driver and pass enger with protective clot hing an[...]

TIPS ON PUTT ING INTO OPER ATION 80 Warning Danger of accident s   Unstable handling ch aracteristics due to slipp ed baggage. – Check the way your bagg age is fixed regularly. – If you carry any baggage , make sure it is fixed firmly as clo se as possible to the cente r of the vehicle and ensure eve n weight distribu- tion between the front [...]

RIDING INST RUCTIONS 81 7 RIDING INSTRUCTIONS 7.1 checks to be made bef ore putting into operatio n Info During operation, the m otorcycle must be in a techn ically perfect condition . In the interest of riding safe ty, you should get into the hab it of making a general chec k of the motorcycle before ev ery journey. – Check the engine oil leve l[...]

RIDING INST RUCTIONS 82 7.2 Starting Danger Danger of poisoning   Exhaust gases are pois onous and can result in unc onsciousness and/or d eath. – When running the engin e, always make sure there is s ufficient ventilation, a nd do not start or run the engine in a c losed space. Note Engine failure   Hig h engine speeds in cold eng ines have [...]

RIDING INST RUCTIONS 83 700248-01 – Press the emergency O FF switch into the position  . – Switch on the ignition by tu rning the black ignition key t o the position  . When you switch on the ign ition, you hear the fuel pump w orking for about 2 sec- onds. At the same time, the f unction test of the combina tion instrument is run. – Sh[...]

RIDING INST RUCTIONS 84 7.4 Shifting, riding Warning Danger of accident s   An abrupt load alteration s can cause the vehicle to ge t out of control. – Avoid abrupt load altera tions and sudden brakin g actions, and adapt your sp eed to the road conditions . Warning Danger of accident s   If you change down at high en gine speed, the rear whe[...]

RIDING INST RUCTIONS 85 Warning Danger of accident s   Reduced road grip with co ld tires. – On every journey, take th e first miles carefully at mod erate speed until the tires re ach operating temperat ure and optimal road grip is ensured. Warning Danger of accident s   Reduced road grip with ne w tires. – New tires have a smooth r oll su[...]

RIDING INST RUCTIONS 86 Note Engine damage   En gine overheating. – If the coolant temperatu re warning lamp lights up, st op the vehicle and switch of f the engine. Let the engine co ol down, and then check the coolant leve l in the radiator and top up if neces sary. If you continue your jo urney with the coolant tem perature warning lamp on, [...]

RIDING INST RUCTIONS 87 – If the EFI  warning lamp  ( MIL ) starts to light up during th e journey, stop immedia tely. If you shift to neutral, the  E FI  warning lamp  ( MI L ) begins to flash. Info From the flash rhythm, yo u can deduce a two-digit num ber, the so-called flash code. The flash code tell s you which component is af[...]

RIDING INST RUCTIONS 88 Warning Danger of accident s   Delayed brake action on s alted roads. – Salt can be deposited on th e brake discs. To achieve th e normal braking effect, th e brake discs must first be cle aned by brak- ing. – When braking, first thro ttle back and then apply the fro nt and rear brakes at the sam e time. – On wet or [...]

RIDING INST RUCTIONS 89 – Do not place the vehicle wh ere there are flammable or e xplosive substances . Note Material damage   Damage and destructio n of components by exces sive load. – The side stand is design ed for the weight of the motorcy cle only. Do not sit on the moto rcycle when it is supported b y the side stand only. The side sta[...]

RIDING INST RUCTIONS 90 Warning Danger of poisoning   Fuel is poisonous and a he alth hazard. – Avoid contact betwe en fuel and skin, eyes an d clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse im mediately with water and contact a do ctor. Wash affected skin ar eas immediately with so ap and water. If fuel is swallowe d, [...]

GREASING A ND SERVICE T ABLE 91 8 GREASING AND SERVICE TA BLE 8.1 Important service ta sks to be carried out by an au thorized KTM-RC8 w orkshop. K10N K75A K150A J1A J2A Engine Change the eng ine oil and filter, clean the oil sc reen.  x ( S. 185) ••••• Check the valve cleara nce and adjust if necessar y.  x • Replace the spark pl[...]

GREASING A ND SERVICE T ABLE 92 K10N K75A K150A J1A J2A Attachments Check bowden c ables for damage, smoo th operation, kink-free ro uting and adjustment.  x ••••• Check the fluid level of the h ydraulic clutch. ( S. 175) • • • • Check the air filter and cha nge if necessary. Clean the a ir filter box.  x • Drain the drain[...]

GREASING A ND SERVICE T ABLE 93 K10N K75A K150A J1A J2A Chassis Check the stee ring head bearing and adju st if necessary.  x ••• Check the swingarm be aring.  x ••• Check deflector.  x • • Check the eccentric sh aft adjustment.  x • • Check all screws to make s ure they are tight.  x ••• Wheels Check the ti[...]

GREASING A ND SERVICE T ABLE 94 8.2 Important service ta sks to be carried out by an au thorized KTM-RC8 w orkshop. (as additio nal job) K150A K300A J1A J2A Completely service fo rk.  x • Completely service s hock absorber.  x • Clean and grease the ste ering head bearing and sea ling elements.  x • • • Clean battery poles and t [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 95 9 MAINTENANCE WORK ON C HASSIS AND ENGINE 9.1 Jacking up motorcyc le front Note Danger of damage   D anger of damage by the veh icle running away or falling o ver. – Always place the vehic le on a firm and even surface. – Jack up the motorcycle r ear end. ( S. 96) 700250-01 – Move the handlebar t[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 96 9.3 Jacking up motorcyc le rear Note Danger of damage   D anger of damage by the veh icle running away or falling o ver. – Always place the vehic le on a firm and even surface. 700251-01 – Insert the work stand ada pter in the rear of the work stand. Work stand adapter (61 029055120) Work stand rea[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 97 9.5 Fork/shock absorb er 700252-01 The fork and the shock abs orber offer many options o f adapting the chassis to yo ur riding style and the payload. Info To help you adapt the vehi cle, we have summarized o ur findings in Table   . Y ou will find the table on the unde rside of the seat. For all d[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 98 700253-01 – Turn adjusting screws   clockwise until they sto p. Info The adjusting screws a re located at the bottom end of th e fork legs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of click s corresponding to the fork t ype. Guideline Compression dam[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 99 700347-01 – Turn adjusting screws   clockwise until they sto p. Info The adjusting screws a re located at the top end of the fork l egs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of click s corresponding to the fork t ype. Guideline Rebound damping Co[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 100 700348-01 – Turn the adjusting spin dles   clockwise until th ey stop. Info The adjusting spindle s are located at the top end of the fo rk legs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of turns c orresponding to the fork ty pe. Guideline Spring pr[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 101 700259-01 – Remove bleeder scre ws   briefly. Any excess pressure e scapes from the interior of th e fork. – Mount and tighten blee der screws. Info Perform this action on bo th fork legs. 9.10 Compression dam ping of the shock absorb er 700340-01 The shock absorber ca n coordinate the compres[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 102 Info The low-speed setting c an be seen during the slow to n ormal compression of th e shock absorber. 700255-01 – Turn the adjusting scre w   clockwise with a screw driver up to the last percepti ble click. Info Do not loosen nut   ! – Turn back counterclo ckwise the number of click s c[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 103 9.12 Adjusting high-spe ed compression dam ping of the shock absorb er Danger Danger of accident s   The shock absorber is un der high pressure. – The shock absorber is fil led with highly compress ed nitrogen, so never dism antle the shock absorbe r or carry out any mainte- nance on it yourself. In[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 104 9.13 Adjusting rebound d amping of the shock abs orber Danger Danger of accident s   The shock absorber is un der high pressure. – The shock absorber is fil led with highly compress ed nitrogen, so never dism antle the shock absorbe r or carry out any mainte- nance on it yourself. 700257-01 – Turn[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 105 Info The spring preload defi nes the initial situation of the s pring process on the shoc k absorber. An optimally adjusted s pring preload is adapted to t he rider's weight and ensu res a compromise betwee n easy handling and stab il- ity. 700341-10 – Take the weight off the rear w heel and swin[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 106 – Turn the adjusting ring cl ockwise and tension it to the s pecified value. Guideline Spring preload Comfort 6  mm (0.24  in) Standard 6  mm (0.24  in) Sport 8  mm (0.31  in) full payload 8  mm (0.31  in) Info Turn clockwise to incre ase preload, turn counter clockwise to redu[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 107 9.15 Steering damper 700339-01 The steering damper su ppresses shocks to the st eering arising from acce leration on uneven ground at high speed or wh en the load is temporarily tak en from the front wheel. The steering damper is a djusted to suit the manner of d riving and the road conditi ons. For hig[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 108 – Adjust the steering dam per according to your ridin g style and the road conditio ns by turning the adjust screw clockwise towards " + ". Guideline Steering damper adj ustment range 1… 32  clicks Recommended rang e for use 1… 20  clicks Standard 1 click Info Do not change the adj[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 109 9.17 Vehicle level 700333-01 Warning Danger of accident s   Modifications to the cha ssis can seriously alter th e vehicle's handling characteri stics. – Following modificat ions, ride slowly at first to get the f eel of the new handling characteristics. The vehicle level can be a djusted at th[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 110 9.18 Adjusting vehicle lev el, front  x Warning Danger of accident s   Modifications to the cha ssis can seriously alter th e vehicle's handling cha racteristics. – Following modificat ions, ride slowly at first to get the f eel of the new handling cha racteristics. 700352-01 – Loosen the [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 111 700353-01 – The fork legs can be fixed at th ree different positions. Guideline Upper triple clamp flus h with upper edge of fork legs 0  mm (0  in) Upper triple clamp flus h with 1st ring of fork legs 2.5  mm (0.098  in) Upper triple clamp flus h with 2nd ring of fork legs (standard) 5 ?[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 112 700331-01 – Loosen screw   but do no t remove it. 700332-01 – Turn the eccentric shaf t   to the desired position us ing the tool from the tool set. Guideline Standard LOW Maximum adjustme nt range between HIGH - LOW 180° Open end wrench SW  3 8 (69012021000) Info You can adjust the [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 113 700334-01 – Tighten screw   . Guideline Remaining chassis s crews M8 25  Nm (18.4  lbf  ft) 9.20 Footrest position 700328-01 The adjustable footre st system enables an indiv idual setting of the footres t height and an individual adjustm ent of the operating elem ents. The lower footres[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 114 700307-01 – Remove screws   . 700308-01 – Position the footrest bra cket with spacers   and s crews. Guideline Standard Lower position Info The adjustable footre st bracket enables a more co mfortable lower footres t posi- tion or a sporting upper foo trest position. 700306-01 – Mount [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 115 700309-01 – Repeat adjustment wo rk on the footrest bracket on th e other side. – Adjust the shift lever. ( S. 11 6) – Adjust the footbrake p edal. ( S. 121)[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 116 9.22 Adjusting shift lever stu b 700304-01 – Remove the screw   wit h the shift lever stub. – Position the shift lever st ub with the screw in one of the hol es   according to the desired lever length. Guideline Standard Central hole – Tighten screw. Guideline Screw, shift lever stub M[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 117 700343-01 – Remove screws   and t ake off the shift rod. – The length of the shift rod ca n be adjusted by means of the s crew thread. Guideline Shift rod 115… 130  mm (4.53… 5. 12  in) – Loosen the counter nut s   . – Adjust the shift shaft. Info Make the same adjustm ents[...]

0 0 A A 0 0 B B 0 0 C C MAINTENA NCE WORK O N CHASSIS AN D ENGINE 118 400479-10 – The shift rod can be mount ed both on the shift lever varia bly at an upper or lower posi- tion, and on the reverse ge ar change of the shift shaft in two d ifferent positions. Guideline Standard   Shift  lev er:  lower  drill  hole, shift  shaf[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 119 700344-01 – The position of the shift lev er can be greatly varied, dep ending on the length of the sh ift rod and the drill holes sele cted. As seen from the footre st, there is either a high positi on of the shift lever   or a low p osition of the shift lever   . Info If you turn the rev[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 120 9.24 Adjusting the footbra ke pedal stub 700305-01 – Remove the screw   wit h the footbrake pedal stub . – Position the footbrake p edal stub with the screw in on e of the holes   accordin g to the desired lever length. Guideline Standard Central hole – Tighten screw. Guideline Screw, [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 121 9.25 Adjusting the footbra ke pedal 700345-01 – Use the tool to press in the an ti-rotation lock   , then t urn the piston rod   . Info The range of adjustmen t is limited. – Remove the tool. The spring tension on the a nti-rotation lock is releas ed and the hex nut is locked. 700346-01 [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 122 9.27 Cleaning the chain Warning Danger of accident s   Oil or grease on the tires redu ces their grip. – Remove oil and grease w ith a suitable cleaning mat erial. Warning Danger of accident s   Reduced braking due to o il or grease on the brake discs . – Always keep the brake di scs free of oil[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 123 9.28 Checking the chain te nsion Warning Danger of accident s   Danger caused by incor rect chain tension. – If the chain tension is too hig h, the components of the se condary power train (cha in, engine sprocket, rear sp rocket, bearings in transmission and rea r wheel) are under addition al load.[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 124 9.29 Adjusting the chain ten sion Warning Danger of accident s   Danger caused by incor rect chain tension. – If the chain tension is too hig h, the components of the se condary power train (cha in, engine sprocket, rear sp rocket, bearings in transmission and rea r wheel) are under addition al load[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 125 700323-01 – Loosen nut   . – Loosen nuts   . – Adjust chain tension by t urning the adjustment sc rews   on the left and right. Guideline Chain tension 15… 20  mm (0.59… 0.79  in) Turn the adjusting scre ws   on the left and right so that th e markings on the left[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 126 9.30 Checking rear spro cket / engine sprocke t for wear 100132-10 – Check the rear sprock et / engine sprocket for w ear. » If the rear sprocket / en gine sprocket are worn: – Change the rear sprock et / engine sprocket, chain a nd chain sliding guard.  x Info The rear sprocket, engi ne sprocke[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 127 9.31 Checking chain wea r 700303-01 – Engage neutral gear. – Pull the lower chain secti on with specified weight   . Guideline Weight, chain wear m easurement 15  kg (33  lb .) – Measure distance   o f 18 chain links in the lower cha in section. Info Chain wear is not always ev e[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 128 9.32 Checking chain slid ing guard 700351-01 – Check the chain sliding g uard for wear at the opening. » If the rivets   of the chain ar e no longer visible at the lowe r edge   of the opening of the chain sliding guard : – Change the chain slidin g guard.  x 9.33 Checking front brak[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 129 9.34 Checking rear brak e disc Warning Danger of accident s   Reduced braking effec t caused by worn brake disc s. – Have worn brake discs re placed immediately in a n authorized KTM-RC8 wo rkshop. 400480-10 – Check the thickness of th e brake disc in several plac es to see if it conforms to meas [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 130 9.36 Checking brake flui d level of front brake Warning Danger of accident s   Failure of brake system . – If the brake fluid level falls b elow the MIN mark, there ma y be a leak in the brake system o r the brake linings are comp letely worn out. Have the brake s ystem checked in an autho rized KTM[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 131 Warning Skin irritations   Bra ke fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – If brake fluid gets into your e yes, rinse thoroughly with w ater and contact a doctor im mediately. Warning Danger of accident s   Reduce[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 132 9.38 Brake linings The brake linings fitted b y KTM have been tested ove r long periods and guarant ee optimal braking chara cteristics. The type nam es of the brake linings are entere d in the homologation doc uments. Info Brake linings availab le in accessories shops ar e often untested and unap prove[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 133 700263-01 – Check the brake linings f or minimum thickness   . Minimum thickness   ≥ 1  mm ( ≥ 0.04  in) » If the minimum thickne ss is less than specified: – Change the front brake lin ings.  x 9.40 Checking rear brak e fluid level Warning Danger of accident s   Fa[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 134 700264-01 – Stand the vehicle uprig ht. – Check the brake fluid lev el of the brake fluid reservoir . » If the fluid level reaches th e  MIN  mark   : – Top up the rear brake fluid.  x ( S. 134) 9.41 Topping up rear brake f luid  x Warning Danger of accident s   Failure of bra[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 135 Warning Environmental ha zard   Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Never user DOT  5 bra ke fluid! This is based on silic one oil and is colored purple . Oil [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 136 Note Danger of accident s   Reduced braking due to d amaged brake discs. – If the brake linings are not ch anged in time, the steel brak e lining carriers grind on the b rake disc. The braking effe ct is greatly reduced and the brake di scs are destroyed. 700266-01 – Check the brake linings f or m[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 137 700272-10 – Loosen screws   and   . – Unscrew screw   abou t 6 turns, press your hand on th e screw to push the wheel spi n- dle out of the fork stub. Remo ve screw   . Warning Danger of accident s   Reduced braking effec t caused by damaged bra ke discs. – Always lay the[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 138 700271-12 – Position the brake calip ers and check that the brake l inings are seated correc tly. – Mount and tighten scre ws   . Guideline Screw, front brake cal iper M10x1.25 45  Nm (33.2  lbf  ft) Loctite ® 243™ – Operate the hand brake le ver several times until the b rake pa[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 139 700311-01 – Remove nut   . Remo ve chain adjuster   . W ithdraw the wheel spin dle   . 700312-01 – Push the rear wheel forwa rds as far as possible and take t he chain off the rear sprocke t. – Pull the rear whell back wards until the brake ca liper support   hang s free be[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 140 9.46 fitting the rear wheel  x Warning Danger of accident s   Reduced braking due to o il or grease on the brake discs . – Always keep the brake di scs free of oil and grease, and c lean them with brake clean er when necessary. Warning Danger of accident s   No braking effect when op erating th[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 141 700313-01 – Remove bushing   an d bushing   . Clean and g rease the roll surfaces of the b ushing and the shaft seal rings. Long-life grease ( S. 224) – Fit the bushings. – Clean the thread of the whe el spindle and nut. – Clean the contact areas o f the brake caliper support a nd sw[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 142 700315-01 – Push the rear wheel forwa rd as far as possible and place t he chain on the rear sprocke t. – Pull the rear wheel back an d push in the wheel spindle. 700316-01 – Lay the chain adjuster   on the tensioning screw. – Position the chain adju ster   and place it on the tens i[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 143 9.47 Checking rear hub sh ock absorbers  x Info The engine power is trans mitted by the rear sprocke t to the rear wheel through 5 sho ck absorbers. They are sub ject to wear during operation. If the shock ab sorbers are not changed in t ime, the rear sprocket carr ier and the rear hub are damag ed. [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 144 Warning Danger of accident s   Uncontrollable hand ling characteristics du e to non-approved and/o r non-recommended tir es/wheels. – Only tires/wheels app roved by KTM and with the corr esponding speed inde x should be used. Warning Danger of accident s   Reduced road grip with ne w tires. – Ne[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 145 9.49 Checking tire air pres sure Info Low tire air pressure lead s to abnormal wear and over heating of the tire. Correct tire air pressure e nsures optimal riding com fort and maximum tire se rvice life. 700268-01 – Remove dust cap. – Check tire air pressure wh en tires are cold. Tire air pressure,[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 146 9.50 Removing the seat 700245-01 – Insert the ignition key in th e seat lock   and turn it anticl ockwise. – Raise the rear of the seat, pu sh it towards the rear, and remo ve it upwards. 9.51 Fitting the seat 700269-01 – Position the recesses o f the seat to the lugs on the frame , lower th[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 147 9.52 Removing passeng er seat 700246-01 – Remove the seat. ( S. 146) – Operate lever   . – Take off the passenger s eat   toward the top. 9.53 Fitting the passenger se at 700275-01 – Position the passeng er seat in the space provided . – Press down the passen ger seat until it clic[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 148 9.54 Mounting helmet lo ck on vehicle 700336-01 – Remove the seat. ( S. 146) – Position the steel cable f rom the toolset with one loop o n the lug   . Steel cable (6001201 5000) – Guide the steel cable thro ugh the helmet opening. – Then position the free loo p of the steel cable on the l[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 149 700276-10 – Disconnect the negat ive (minus) cable   of the ba ttery. 700277-10 – Remove the plus pole co ver. – Disconnect the positi ve (plus)   cable of the batt ery. 700278-01 – Remove screws   . – Removing the securin g bracket   . – Pull the battery upwards o ut[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 150 9.56 Installing the battery  x 700279-01 – Position the battery in the b attery rack. Info The poles of the battery mu st face the rear of the vehicle. – Position the bracket   . 700277-11 – Mount and tighten scre ws   . Guideline Remaining chassis s crews M6 10  Nm (7.4  lbf [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 151 700276-11 – Reconnect the negati ve (minus) cable   of the ba ttery. – Fit the seat. ( S. 146) 9.57 Recharging the batt ery  x Warning Risk of injury   Batter y acid and battery gases cau se serious cauterizati on. – Keep batteries out of the re ach of children. – Wear suitable protec[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 152 Warning Environmental ha zard   Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Even if there is no load on the ba ttery, it loses power every da y. The charge state and the [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 153 100151-10 – Connect the battery cha rger to the battery. Switch on th e battery charger. Battery charger  (584 29074000) You can also use the batte ry charger to test rest potenti al and start potential of the ba t- tery, and to test the genera tor. With this device, you can not overcharge the batt[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 154 Info The main fuse protects a ll power-consuming com ponents of the vehicle. T he main fuse is under the seat . – Switch off all power-con suming components an d switch off the engine. – Remove the seat. ( S. 146) 700280-01 – Remove protection co vers   . – Remove a defective ma in fuse ?[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 155 9.59 Changing fuses of in dividual power consu mers Info The fuse box containin g the fuses of individual pow er consumers is located u nder the seat. – Switch off all power-con suming components an d switch off the engine. – Remove the seat. ( S. 146) 700281-01 – Open the fuse box cover   .[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 156 – Remove defective fus e. Guideline Fuse  1 - 10A - ignition, co mbination instrume nt, immobilizer, alarm s ystem (optional) Fuse  2 - 15A - high beam , low beam, parking ligh t, tail light, license plate lamp Fuse  3 - 10A - horn, brake light Fuse  4 - 10A - radiator fan Fuse  5 - 10A[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 157 Warning Fire hazard   The elec trical system can be over loaded by the use of incorrec t fuses. – Use only fuses with the pre scribed amperage. Ne ver by-pass or repair fuses . – Use spare fuses with the c orrect rating only. Fuse  (7501108801 0) ( S. 213) Fuse  (7501108801 5) ( S. 213) Info[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 158 700293-01 – Fold up the combinatio n instrument. Pull the lug   out of the rubber holder   . – Remove the rubber hold er. 700294-01 – Release the latch   . – Remove the lamp cove r   . 700295-01 – Disconnect plug-in co nnector   . – Push off the retaining cla mp[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 159 700296-01 – Position the new headl ight bulb in the headlight hou sing. Low beam / high beam  (H7 ) ( S. 213) Info Insert the headlight bul b so that the lug   is position ed in the cut-out. – Position the retaining c lamp. – Position the plug-in con nector. 400422-10 – Position the lug[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 160 700293-11 – Position the rubber hold er   . – Fold down the combina tion instrument. Positio n the lug   in the rubber ho lder. 9.61 Change the high beam bulb. Note Damage to reflector   Keep the glass of the bulb fre e of grease. – Clean the glass bulb with a c lean cloth befo[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 161 700297-01 – Remove screws   . Re move cover. 700298-01 – Release the latch   . – Remove the lamp cove r   .[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 162 700299-01 – Disconnect plug-in co nnector   . – Push off the retaining cla mp   on both sides, sque eze and fold to the side. – Remove headlight bu lb. – Position the new headl ight bulb in the headlight hou sing. Low beam / high beam  (H7 ) ( S. 213) Info Insert the headlight bul[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 163 400422-11 – Position the lug   of the lam p cover in the notch. Engag e the latch. – Check lighting functio n. 700335-10 – Position cover. Info Check for correct positi oning and freedom of move ment of the brake lines. – Mount and tighten scre ws   . Guideline Remaining chassis s cr[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 164 9.62 Changing the parkin g light bulb Note Damage to reflector   Keep the glass of the bulb fre e of grease. – Clean the glass bulb with a c lean cloth before mountin g. Any grease on the glass wi ll evaporate by the heat and be d eposited on the reflector. – Switch off all power-con suming compon[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 165 700298-01 – Release the latch   . – Remove the lamp cove r   . 700300-01 – Pull the parking light   c arefully out of the holder. – Remove the light bulb. – Position a new light bulb in t he holder. Parking light  (W2,1x 9,5d) ( S. 213) – Carefully position the h older w[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 166 400422-12 – Position the lug   of the lam p cover in the notch. Engag e the latch. – Check lighting functio n. 700335-11 – Position cover. Info Check for correct positi oning and freedom of move ment of the brake lines. – Mount and tighten scre ws   . Guideline Remaining chassis s cr[...]

0 0 B B 0 0 A A MAINTENA NCE WORK O N CHASSIS AN D ENGINE 167 9.63 Checking headlig ht adjustment 400420-10 – On a light-colored wall be hind a horizontal area, mak e a mark as high as the center of the low beam headlight. – Make another mark at a dis tance of   under the first m ark. Guideline Distance   5  cm (2  in) – Sta[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 168 700285-01 – Adjust the beam distan ce of the headlight by turning s crew   . Guideline The boundary betwee n light and dark must be exact ly on the lower mark for a motor- cycle with a rider (mark is ap plied under: Checking he adlight adjustment). Info Turn clockwise to incre ase the light rang[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 169 – Switch on the ignition by tu rning the black ignition key t o the position  . EFI  warning lamp   ( MIL ) lig hts up, switches off, and the n starts to flash. The immobilizer indicator la mp  lights up, switches of f briefly, and switches on again. – Switch off the ignition by tu rn[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 170 – Switch on the ignition by tu rning the orange program ming key to the position  . EFI  warning lamp   ( MIL ) lig hts up, switches off, and the n starts to flash. The immobilizer indicator la mp  lights up, switches of f briefly, and flashes according to the numbe r of functioning bla[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 171 – To activate further ignit ion keys, repeat the last 4 step s with the respective ignit ion key. – Insert the orange progra mming key in the ignition lo ck. – Switch on the ignition by tu rning the orange program ming key to the position  . EFI  warning lamp   ( MIL ) lig hts up, swit[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 172 400416-10 Cooling takes place by m eans of the air stream and a rad iator fan   , which is contr olled by a thermoswitch. The lower the speed, the le ss the cooling effect. Dirty co oling fins also reduce the c ooling effect. 9.67 Checking the coolan t level Warning Danger of scalding   The cool[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 173 – Check the coolant leve l in the compensating tank . The coolant level mu st be between  MIN and  M AX . » If there is no coolant in the co mpensating tank: – Check the cooling syst em for leaks.  x Info Do not operate the motorc ycle! » If the coolant level in the co mpensating tank doe[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 174 Note Engine damage   Aft er draining coolant and ref illing the cooling system , the motorcycle must be rai sed at the front according to th e model type. This is the only way of en suring that the cooling sys tem is filled without air bubb les. Air in the cooling system can lead to engine fail- ure. [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 175 9.69 Adjusting basic posit ion of clutch lever 700283-01 – Adjust the basic setting o f the clutch lever to your hand s ize by turning adjusting screw   . Info Turn the adjusting scre w clockwise to increase th e distance between the clu tch lever and the handleba r. Turn the adjusting scre w co[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 176 700350-01 – Check the fluid level. The fluid level must be bet ween the  MIN and  MAX  markings. » If the fluid level does n ot meet specifications : – Correct the fluid level o f the hydraulic clutch. ( S. 1 76) 9.71 Correcting fluid leve l of hydraulic clutch Info The fluid level rises w[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 177 9.72 Adjusting gas Bowd en cable  x 700317-01 – Move the handlebar to th e straight-ahead positio n. – With the diagnostics to ol  KTM  DIA , place the con trol motor for the throttle valv e position into the neutral position . – Loosen the counter nut   . – Adjust the gas Bowden [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 178 9.74 Adjusting handleb ar height Info The handlebar stub pos ition must be identical on th e left and the right of the vehicle . 700318-01 – Loosen screw   . Info Loosen the screw seve ral turns to prevent damag ing the fork lacquer when mo v- ing the handlebar stub. – Remove screw   . 7[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 179 700320-01 – Tighten the screw. Guideline Screw, handlebar stu b M8 20  Nm (14.8  lbf  ft) – Repeat the adjustmen ts on the other handlebar stu b. – Move the handlebar to an d fro over the entire steering ra nge. » If the cables restrict th e freedom of movemen t of the steering: – Corr[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 180 9.76 Adjusting rear frame p osition Warning Danger of accident s   Modifications to the cha ssis can seriously alter th e vehicle's handling cha racteristics. – Following modificat ions, ride slowly at first to get the f eel of the new handling cha racteristics. 700327-10 Setting a higher seat [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 181 700327-11 – Remove screw   with wa sher on the left and right side o f the vehicle. – Press the rear end up until th e drill holes of the frame are leve l with the lower rear drill holes of the frame rear . – Fit the screw and washer o n the left and right sides of the veh icle, and tighten.[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 182 700338-01 – When you screw in the rea r left fixing screw, the plug-in c able binder   is pushe d out of the thread. To reposi tion the cable of the lambda pr obe, fix the plug-in cable binder in the remaining fr ee drill hole. Info Check the cable routing . The cable of the lambda prob e must n[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 183 700327-14 – Remove screw   with wa sher on the left and right side o f the vehicle. – Press the rear end up until th e drill holes of the frame are leve l with the upper front drill holes of the frame rear . 700329-01 – Fit the screw and washer o n the left and right sides of the veh icle, a[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 184 700338-11 – When you screw in the rea r left fixing screw, the plug-in c able binder   is pushe d out of the thread. To reposi tion the cable of the lambda pr obe, fix the plug-in cable binder in the remaining fr ee drill hole. Info Check the cable routing . The cable of the lambda prob e must n[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 185 700301-10 – Remove oil dipstick   . Check the engine oil leve l in the measurement rang e. Info After switching off the eng ine, wait one minute before c hecking the level. The engine oil level mus t be in the middle   of the meas urement range of the oil dipstick. » If the enigne oil lev[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 186 Warning Environmental ha zard   Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Drain the engine oil only wh en the engine is warm. 700302-10 – Remove screws   . – [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 187 700287-01 – Stand the motorcycle o n its side stand on a horizonta l surface. – Place a suitable contai ner under the engine. – Remove the oil drain plug   with the magnet, O-ring s and oil screen. – Remove the oil filter.  x ( S. 188 ) – Completely drain the en gine oil. 700292-01 ?[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 188 700302-10 – Position the left exhaus t cover   . – Mount and tighten scre ws   . Guideline Remaining chassis s crews M5 5  Nm (3.7  lbf  ft) 9.80 Removing oil filter  x Warning Danger of scalding   Engine oil and gear oil get ver y hot when the motocycle is d riven. – Wea[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 189 Warning Environmental ha zard   Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. – Place a suitable contai ner under the engine. 700289-01 – Remove screws   . R emove the[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 190 9.81 Fitting oil filter  x 700291-01 – Insert the oil filter   . – Lubricate the O-ring o f the oil filter cover. Fit the o il filter cover   . – Mount and tighten scre ws. Guideline Remaining engine sc rews M5 6  Nm (4.4  lbf  ft) 9.82 Filling up with engine oil  x Info[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 191 – Remove the dipstick   and top up the engine oil. Engine oil (1st quantity) 3.00  l (3.17  qt.) Ext ernal temperature: ≥ 0  °C ( ≥ 32  °F) Engine oil (SAE 10W/50) ( S. 222) External temperature: <  0  °C (<  32  °F) Engine oil (SAE 5W/40) ( S. 222) ?[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 192 Danger Danger of poisoning   Exhaust gases are pois onous and can result in unconsciousness a nd/or death. – When running the engin e, always make sure there is s ufficient ventilation, and do not start or run the engi ne in a closed space. – Start the engine and chec k that it is oil-tight. – C[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 193 – Remove the dipstick   and top up the engine oil. Condition External temperature : ≥ 0  °C ( ≥ 32  °F) Engine oil (SAE 10W/5 0) ( S. 222) Condition External temperatu re: <  0  °C (<  32  °F) Engine oil (SAE 5W/40 ) ( S. 222) Info For optimal performa nce o[...]

TROUBLES HOOTING 194 10 TROUBLESHOOTING Faults Possible cause Action Engine doesn't crank w hen the electric starter button is presse d Operating error – Carry out the steps for start ing. ( S. 82) Battery discharged – Recharge the battery.  x ( S. 151) – Check closed-circu it current.  x Fuse  1 , or  6 blown – Cha nge the[...]

TROUBLES HOOTING 195 Faults Possible cause Action Engine cranks but do esn't start Fuel pump contro l defective – Check fuel pump contro l.  x Fuel quality insufficie nt – Add suitable fuel. Engine has too little powe r Air filter very dirty – Change the air filter.  x Fuel filter very dirty – Chang the fuel filter.  x Fault i[...]

TROUBLES HOOTING 196 Faults Possible cause Action Brake light and horn do not w ork Fuse  3 blown – Change the fus es of individual power consumers. ( S. 155) Battery discharged Ignition not switched of f when vehicle parked – Recharge the battery.  x ( S. 151) Battery is not charged by th e generator – Check charging volta ge.  x Co[...]

IMMOBILI ZER FLASH COD E 197 11 IMMOBILIZER FLASH CODE Fault Description Possible cause Action 12 Immobilizer indicator lamp flashes 1x short, 1 secon d pause, 2x short All ignition keys inactiv e – A ctivate/deactivate the i gni- tion key. ( S. 168) 13 Immobilizer indicator lamp flashes 1x short, 1 secon d pause, 3x short Malfunction, anten na o[...]

ENGINE CON TROL FLASH C ODE 198 12 ENGINE CONTROL FLA SH CODE Fault Description Possible cause Action 02 EFI  Warning lamp  ( MIL ) flashes 2x short Malfunction in ignitio n pulse generator circuit – Check the ignition puls e generator.  x 06 EFI  Warning lamp  ( MIL ) flashes 6x short Input signal of throttle valve position genera[...]

ENGINE CON TROL FLASH C ODE 199 Fault Description Possible cause Action 13 EFI  Warning lamp  ( MIL ) flashes 1x long, 3x short Input signal from inta ke air temperatur sensor to o high – Check the intake air temp er- ature sensor.  x 14 EFI  Warning lamp  ( MIL ) flashes 1x long, 4x short Input signal of pressu re sensor ambient a[...]

ENGINE CON TROL FLASH C ODE 200 Fault Description Possible cause Action 41 EFI  Warning lamp  ( MIL ) flashes 4x long, 1x short Interruption/short- circuit to ground in fuel pump cont rol circuit – Check fuel pump control.  x Short-circuit to plus in fue l pump control circuit – Check fuel pump control.  x 45 EFI  Warning lamp ?[...]

ENGINE CON TROL FLASH C ODE 201 Fault Description Possible cause Action 62 EFI  Warning lamp  ( MIL ) flashes 6x long, 2x short Malfunction in idling co ntrol system – Check idle speed control.  x 68 EFI  Warning lamp  ( MIL ) flashes 6x long, 8x short Connection of pressu re sensor, induction manifold (c ylinder 1) leaky – Check[...]

CLEANING 20 2 13 CLEANING 13.1 Cleaning motorcyc le Note Material damage   Damage and destructio n of components by high-p ressure cleaning equip ment. – Never clean the vehicl e with high-pressure clea ning equipment or a strong w ater-jet. The excessive p ressure can penetrate e lectrical components, conne cts, Bowden cables, and b earings, e[...]

CLEANING 20 3 Warning Danger of accident s   Reduced braking due to w et or dirty brakes. – Clean or dry dirty or wet brake s by riding and braking gent ly. – After cleaning, ride a sho rt distance until operating t emperature is reached , and apply the brakes. Info The heat causes water to e vaporate from inaccess ible parts of the engine an[...]

CONSERV ATION FOR WI NTER OPERA TION 204 14 CONSERVATION FOR WI NTER OPERATION 14.1 Conservation for wi nter operation Info If you use the motorcycle i n the winter, you have to expec t salt on the roads. You theref ore have to take precaution s against the aggressive road salt. If the vehicle has been use d on salted roads, clean it with c old wat[...]

STORAGE 205 15 STORAGE 15.1 Storage Info If you want to garage the mot orcycle for a longer period, ta ke the following actions . Before storing the moto rcycle, check all parts for fun ction and wear. If service, re pairs or replacements ar e necessary, you should do this during the storage p eriod (less workshop ove rload). In this way, you can a[...]

STORAGE 206 – Cover the motorcycle w ith a porous sheet or blanket . Info Do not use non-porous m aterials since they preve nt humidity from escapin g, thus causing corrosio n. Avoid running the engin e for a short time only. Since the e ngine cannot warm up pro perly, the water vapor produ ced during combustion conden ses and causes valves an d [...]

TECHNICA L DATA - ENGINE 207 16 TECHNICAL DATA - ENGIN E Design 2-cylinder 4-stroke Ot to motor, 75° V arrangemen t, water-cooled Displacement 1,15 0  cm³ (70.18  cu  in) Stroke 69  mm (2.72  in ) Bore 103  mm (4.06  in ) Compression ratio 12,5:1 Control DOHC, 4 valves per cy linder, chain-driven Valve - diameter Intake 42 ?[...]

TECHNICA L DATA - ENGINE 208 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronically contr olled fuel injection Ignition system Contactless control led fully electronic ignitio n with digital ignition adjustment Generator 12  V, 390  W Spark plug NGK LKAR9BI9 Electrode gap, spark pl ug 0.8… 0.9  mm [...]

TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 209 17 TECHNICAL DATA - ENGINE T IGHTENING TORQUES Hose clip, intake flang e M4 1.5  Nm (1.11  lbf  ft) – Screw, gear sensor M 5 3  Nm (2.2  lbf  ft) Lo ctite ® 243™ Screw, pulse generato r M5 10  Nm (7.4  lb f  ft) Loctite ® 243™ Screw, bearing retaine r M5 6  Nm ([...]

TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 210 Screw, stator clamp M6 10  Nm (7.4  lb f  ft) Loctite ® 243™ Plug, vacuum connect ion M6 5  Nm (3.7  lbf  ft) Lo ctite ® 243™ Screw, valve cover M6 10  Nm (7.4  lbf  ft) – Screw, water pump co ver M6 10  Nm (7.4  lbf  ft) – Screw, water pump wh eel M6 10[...]

TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 211 Screw, conrod bearing M10x1 Step 1 25  Nm (18.4  lbf  ft) Step 2 30  Nm (22.1  lbf  ft) Step 3 90° – Plug, cam lever axis M10x1 15  Nm (11.1  lbf  ft) – Screw, cylinder head M11x1 .5 Step 1 15  Nm (11.1  lbf  ft) Step 2 30  Nm (22.1  lbf  ft) Step 3 [...]

TECHNICA L DATA - CHASS IS 212 18 TECHNICAL DATA - CHAS SIS Frame Lattice frame made of ch romium molybdenum s teel tubing, powder-coated Fork WP  Suspension U p Side Down 4354 Shock absorber WP  Suspension  401 4 VP Suspension travel front 120  mm (4.72  i n) rear 125  mm (4.92  in ) Brake system front Double disc brake with r[...]

TECHNICA L DATA - CHASS IS 213 Chain 5/8  x  5/16” X ‑ r ing Steering head angle 66.7° Wheelbase 1,435  m m (56.5  in) Seat height, unloade d Lower frame rear posi tion 805  mm (31.69  in) Upper frame rear pos ition 825  mm (32.48  in) Ground clearance, un loaded 110  mm (4.33  in) Weight without fuel 188  kg ([...]

TECHNICA L DATA - CHASS IS 214 Brake/tail light LED License plate lamp W2,1x9,5d 12  V 5  W Front tire Rear tire 120/70  ZR  17  58  W  T L Pirelli Dragon  Supe rcorsa  Pro 190/55  ZR  17  75  W  T L Pirelli Dragon  Supe rcorsa  Pro For further information , see the Service section un der: http://www.[...]

TECHNICA L DATA - FORK 215 19 TECHNICAL DATA - FORK Fork part number 05.18.7D.07 Fork WP  Suspension U p Side Down 4354 Compression damp ing Comfort 15  clicks Standard 10  clicks Sport 5  clicks full payload 5  clicks Rebound damping Comfort 15  clicks Standard 10  clicks Sport 5  clicks Full payload 5  clicks Spring pre[...]

TECHNICA L DATA - SHOCK A BSORBER 216 20 TECHNICAL DATA - SHOCK AB SORBER Shock absorber part n umber 17.18.7D.07 Shock absorber WP  Suspension  401 4 VP Compression damp ing, high-speed Comfort 2  turns Standard 1.5  turns Sport 1  turn full payload 1  turn Compression damp ing, low-speed Comfort 20  clicks Standard 15  cli[...]

TECHNICA L DATA - SHOCK A BSORBER 217 Spring length 160  mm (6.3  in) Gas pressure 10  bar (145  psi) Static sag 15  mm (0.59  in) Riding sag 30  mm (1.18  in) Inbuilt length 290  mm (11.42  in)[...]

TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 218 21 TECHNICAL DATA - CHASSIS T IGHTENING TORQUES Screw, side stand switc h M4 2  Nm (1.5  lbf  ft) Loctite ® 243™ Screw, brake fluid res ervoir of rear brake M5 5  Nm (3.7  lbf  ft) Loctite ® 243™ Screw, brake line holde r M5 5  Nm (3.7  lbf  ft) – Screw, chain sli[...]

TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 219 Screw, front brake dis c M8 30  Nm (22.1  lbf  ft) Loctite ® 243™ Screw, spring holder on s ide stand bracket M8 15  Nm (11.1  lbf  ft ) Loctite ® 243™ Screw, rear footrest br acket M8 25  Nm (18.4  lbf  ft) – Screw, front footrest b racket M8 25  Nm (18.4  [...]

TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 220 Screw, connecting lev er, shock absorber deflector M10 45  Nm (33.2  lbf  ft) Loctite ® 243™ Remaining chassis s crews M10 45  Nm ( 33.2  lbf  ft) – Nut, deflection lever on f rame M14x1.5 100  Nm (73.8  lbf  ft) – Lambda probe M18x1.5 45  Nm (33.2  lbf  f[...]

SUBSTAN CES 221 22 SUBSTANCES Brake fluid DOT  4  /  D OT  5.1 according to – DOT Specification – Use only brake fluid that c omplies with the specifie d standards (see specifi cations on the container) a nd that possesses the cor re- sponding properties . KTM recommends  Cas trol and  Motorex ® prod ucts. Suppler Castrol –[...]

SUBSTAN CES 222 Engine oil (SAE 10W /50) according to – JASO  T903  MA ( S. 226) – SAE ( S. 226) (SAE 10W/50) Specification – Use only engine oils tha t comply with the specified s tandards (see specific ations on the container) an d that possess the corresp onding properties. KTM recom mends Motorex ® produ cts. fully synthetic engine[...]

SUBSTAN CES 223 Fork oil (SAE 5) according to – SAE ( S. 226) (SAE 5) Specification – Use only oils that compl y with the specified standa rds (see specifications o n the container) and that pos sesses the correspon ding prop- erties. KTM recommen ds Motorex ® products. Suppler Motorex ® – Racing  Fork  Oil Hydraulic fluid (15) accord[...]

AUXILIARY S UBSTANC ES 224 23 AUXILIARY SUBSTANCES Chain cleaner Specification – KTM recommends  M otorex ® products. Suppler Motorex ® – Chain  Clean  611 Cleaning and polish ing materials for metal, r ubber and plastic Specification – KTM recommends  M otorex ® products. Suppler Motorex ® – Protect  &  Shine  [...]

AUXILIARY S UBSTANC ES 225 Motorcycle cleane r Specification – KTM recommends  M otorex ® products. Suppler Motorex ® – Moto  Clean  900 Onroad chain spray Specification – KTM recommends  M otorex ® products. Suppler Motorex ® – Chain  Lube  622  Stron g Universal oil spray Specification – KTM recommends  M oto[...]

STANDAR DS 226 24 STANDARDS JASO  T903  MA Different technical de velopment directions re quired a new specificat ion for 4-stroke motorcyc les – the JASO T903 MA Stan dard. Ear- lier, engine oils from the au tomobile industry were u sed for 4-stroke motorcy cles because there was no s eparate motorcycle sp ecification. Whereas long service[...]

INDEX 227 INDEX B Battery f i t t i n g .................................... 1 5 0 r e c h a r g i n g ................................. 1 5 1 r e m o v i n g .................................. 1 4 8 Blank time of the LAP  but ton LAP  BLANK  T a d j u s t i n g ................................... 6 5 Brake disc of rear brake c h e c k i n[...]

INDEX 228 E Electric starter butt on ............................. 2 3 Emergency OFF switc h ............................. 2 2 Engine r u n n i n gi n .................................. 7 8 Engine number .................................. 1 7 Engine oil c h a n g i n g .................................. 1 8 5 d r a i n i n g .......................[...]

INDEX 229 c h e c k i n g .................................. 1 6 7 Headlight flasher s witch ............................ 2 0 H e l m e t l o c k ................................... 7 4 f i t t i n gt o v e h i c l e ............................. 1 4 8 High beam bulb c h a n g i n g .................................. 1 6 0 Horn button .............[...]

INDEX 230 P Parking ...................................... 8 8 Parking light bulb c h a n g i n g .................................. 1 6 4 Passenger footres ts ............................... 7 4 Passenger seat m o u n t i n g ................................. 1 4 7 r e m o v i n g .................................. 1 4 7 Play in gas Bowden cabl e [...]

INDEX 231 Shock absorber part n umber ......................... 1 8 Side stand ..................................... 7 6 Spare parts, accesso ries ............................ 8 Starting ...................................... 8 2 S t e e r i n g d a m p e r ............................... 1 0 7 a d j u s t i n g .................................. 1[...]

KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 02/2008 Photo Mitterbauer *32112 50en* 3211250en[...]