KTM 1190 RC8 R Track Owner's Manual
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KTM 1190 RC8 R Track Owner's Manual

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OWNER'S MANUAL
2011
1190 RC8 R TRACK
Art. no. 3211609en

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Summary of Contents for KTM 1190 RC8 R Track

  • Page 1 OWNER'S MANUAL 2011 1190 RC8 R TRACK Art. no. 3211609en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Hiding the external temperature display......34 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Opening the filler cap ............ 35 IMPORTANT INFORMATION ..........5 Closing the filler cap............35 VIEW OF VEHICLE............... 7 Shift lever..............35 View of vehicle, front left side........... 7 Foot brake lever.............
  • Page 5 TABLE OF CONTENTS Checking the chain tension ..........62 TECHNICAL DATA - ENGINE TIGHTENING TORQUES..97 Adjusting the chain tension ..........62 TECHNICAL DATA - CHASSIS ..........99 Checking the chain, rear sprocket and engine sprocket..63 Tires ................99 Adjusting basic position of clutch lever......

  • Page 6: Means Of Representation

    All jobs marked with this symbol require specialist knowledge and technical understanding. In the interests of your own safety, have these jobs done in an authorized KTM-RC8 workshop! There, your motorcycle will be han- dled optimally by specially trained experts with the necessary special tools.

  • Page 7: Important Information

    The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be met for damage result- ing from manipulation and/or other changes to the vehicle.
  • Page 8 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side 601394-10 Clutch lever ( p. 10) Handwheel for the spring preload on the shock absorber Engine oil fuel filler Quick shifter ( p. 83) Shift lever ( p. 35)

  • Page 10: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side 601395-10 Vehicle identification number/type label ( p. 9) Emergency OFF switch ( p. 10) Electric starter button ( p. 10) Hand brake lever ( p. 10) Foot brake lever ( p. 36) Engine number ( p.

  • Page 11: Serial Numbers

    SERIAL NUMBERS Vehicle identification number/type label The vehicle identification number is stamped on the frame behind the steering head  on the right. The type label is on the frame above the chassis number.  601396-10 Engine number The engine number is stamped on the right side of the engine.

  • Page 12: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulic and self-adjusting. 601399-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar.  The hand brake lever operates the front brake.

  • Page 13: Quick Shifter Switch

    CONTROLS Quick shifter switch The quick shifter switch is located on the left next to the combination instrument.  Possible states Quick shifter on – The quick shifter switch is flipped up. • Quick shifter off – The quick shifter switch is flipped down. •...

  • Page 14: Combination Instrument - Activation And Test

    The speed display counts from 0 to 300 and back. The remaining display segments outside the info display light up briefly. The KTM logo appears in the info display. In ROAD mode, the info display switches to ODO, Trip 1, Time 1, Avs 1 mode.

  • Page 15: Info Display

    CONTROLS Info display 5.11 The info display has the ROAD mode and RACE mode menu interfaces.  If the general warning lamp lights up, the corresponding message is shown periodi- cally on the info display. Information repeat 45 s The information shown on the info display can be controlled with the function buttons. 400580-13 Indicator lamps 5.12...
  • Page 16 CONTROLS SERVICE IN xxx KM(MPH) appears on the info display if the distance to the next service falls below the specified value. Distance 500 km (310.7 mi) 400472-01 HIGH TEMP appears on the info display if the coolant temperature rises above the speci- fied value.

  • Page 17: Combination Instrument - Road Mode Overview

    CONTROLS Combination instrument - ROAD mode overview 5.14 401208-10 Functions in ROAD mode Odometer menu, ODO/Trip 1 Odometer menu, ODO/Trip 2 FUELDISTANCE menu DISTANCE TO Next Service menu Odometer menu, ODO/Trip 1 5.15 Condition Alternative 1 • The ignition is on. •...

  • Page 18: Odometer Menu, Odo/Trip 2

    CONTROLS Press the The display of Trip 1, Time 1 and Avs 1 is reset MODE button for 3 - 5 seconds. Press the Next display mode MODE button briefly. Odometer menu, ODO/Trip 2 5.16 Condition Alternative 1 • The ignition is on. •...

  • Page 19: Next Service Menu, Distance To Next Service

    CONTROLS Press the button The display changes to the SET‑UP menu and the button for 3 - 5 seconds. Press the No function MODE button for 3 - 5 seconds. Press the Next display mode MODE button briefly. Next service menu, DISTANCE TO Next Service 5.18 Condition •...

  • Page 20: Combination Instrument - Race Mode Overview

    CONTROLS Combination instrument - RACE mode overview 5.19 400943-10 Functions in RACE mode LAPSTOGO menu Maximum lap speed menu, TOPSPEED Lap time, LAP/BESTLAP/LastLap menu Top speed, LAP/BESTLAP/TopSpeed menu Total distance in Race mode menu, RACEODO Remaining laps menu, LAPSTOGO 5.20 Condition Alternative 1 •...

  • Page 21: Maximum Lap Speed Menu, Topspeed

    CONTROLS Press the button The display changes to the SET‑UP menu and the button for 3 - 5 seconds. Press the All values in RACE mode are reset (except RACEODO) MODE button for 3 - 5 seconds. Press the Next display mode MODE button briefly.

  • Page 22: Maximum Speed Menu, Lap/Bestlap/Topspeed

    CONTROLS Press the button The display changes to the SET‑UP menu and the button for 3 - 5 seconds. Press the All values in RACE mode are reset (except RACEODO) MODE button for 3 - 5 seconds. Press the Next display mode MODE button briefly.

  • Page 23: Combination Instrument - Set-Up Mode

    CONTROLS Combination instrument - SET‑UP mode 5.25 401209-01 Settings in SET‑UP mode Mode menu, CHANGE MODE Time menu, SET CLOCK SETTINGS menu UNITS menu OPTIONS menu EXIT SETUP menu SET‑UP menu 5.26 Condition Alternative 1 • The ignition is on. •...

  • Page 24: Mode Menu, Change Mode

    CONTROLS Press the button No function and the button for 3 - 5 seconds. Press the The menu in front of the arrow is selected MODE button for 3 - 5 seconds. Press the The menu in front of the arrow is selected MODE button briefly.

  • Page 25: Settings Menu

    CONTROLS Press the Open and exit SET CLOCK or change to the next value MODE button briefly. SETTINGS menu 5.29 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. • ROAD mode Alternative 2 • The ignition is on. •...

  • Page 26: Blank Time Menu, Lap, Lap Blank Time Button

    CONTROLS Press the Open and exit SHIFT RPMS or change to the next value MODE button for 3 - 5 seconds. Press the Open and exit SHIFT RPMS or change to the next value MODE button briefly. Blank time menu, LAP, LAP BLANK TIME button 5.31 Condition Alternative 1...

  • Page 27: Fuel Reserve Display Menu, Trip F Reset

    CONTROLS Press the button No function and the button for 3 - 5 seconds. Press the Open and exit SET NUM LAPS MODE button for 3 - 5 seconds. Press the Open and exit SET NUM LAPS MODE button briefly. Fuel reserve display menu, TRIP F RESET 5.33 Condition...

  • Page 28: Kilometers/Miles Menu, Set Km/Miles

    CONTROLS – Press the MODE button briefly. In the SET KM/MILES menu, you can set the units for measuring speed and distance. In the SET °C/°F menu, you can set the unit for the temperature display. In the BACK… menu, you can switch back to the SET‑UP menu. The symbol indicates which menu can be activated with the MODE button.

  • Page 29: Additional Functions Menu, Options

    CONTROLS – Press the MODE button briefly. – Press the button once until the symbol shows SET °C/°F in the info display. – Press the MODE button briefly. In the SET °C/°F menu, you can set the unit for the temperature display. Press the button .

  • Page 30: External Temperature Display Menu, Option Outtemp

    CONTROLS • RACE mode – Press the button and the button for 3 - 5 seconds. – Press the button four times until the symbol shows OPTIONS in the info dis- play. – Press the MODE button briefly. – Press the MODE button briefly. In the OPTION TPMS menu, you can switch the tire pressure check on/off (available as accessory).
  • Page 31 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button ton for 3 - 5 sec- ton briefly. 3 - 5 seconds. onds. Odometer menu, No function No function The display...
  • Page 32 CONTROLS Table of functions Display Press the button Press the button Press the button Press the MODE but- Press the MODE but- and the button ton for 3 - 5 sec- ton briefly. 3 - 5 seconds. onds. Additional functions The arrow moves The arrow moves No function...

  • Page 33: Displaying Lap Times

    CONTROLS Displaying lap times 5.40 Condition The ignition is on. The motorcycle is stationary. RACE mode – Press tje MODE button briefly and repeatedly until LAP/BESTLAP/LastLap appears in the info display. LAP01 appears on the left of the info display. –...

  • Page 34: Adjusting Shift Speed Rpm1/2

    CONTROLS – Set the minutes with the button or the button. – Press the MODE button briefly. The settings are stored and the display changes to the SET‑UP menu. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display.

  • Page 35: Setting The Number Of Laps Set Num Laps

    CONTROLS With the LAP BLANK TIME function, you can prevent the lap from being timed too short. This may happen if you accidentally press the LAP button twice in a row. – Set the blank time of the LAP button with the button or the button.

  • Page 36: Setting The Temperature Unit Set °C/°F

    CONTROLS – Press the button and the button for 3 - 5 seconds. – Press the button three times until the symbol shows UNITS in the info display. – Press the MODE button briefly. – Press the MODE button briefly. The selected unit appears on the left of the display.

  • Page 37: Opening The Filler Cap

    CONTROLS – Press the MODE button briefly. – Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display. – Press the MODE button briefly. Opening the filler cap 5.50 Danger Fire hazard Fuel is highly flammable. –...

  • Page 38: Foot Brake Lever

    CONTROLS The gear positions can be seen in the figure. The neutral or idle position is between the first and second gear.  Info The arrangement of the gears is the reverse of that in RC8 R, which is approved for public road use.

  • Page 39: Putting Into Operation

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out exclusively by an authorized KTM-RC8 workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 40: Running The Engine In

    PUTTING INTO OPERATION Running the engine in – Do not exceed the specified engine speed and load during the running-in period. Guideline Maximum engine speed During the first: 250 km (155.3 mi) 7,500 rpm After the first: 250 km (155.3 mi) 10,500 rpm –...

  • Page 41: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 42: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM RC8 workshop will be pleased to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 43: Service Schedule

    • • • • • • Read out the trouble code memory using the KTM diagnostics tool. Check the measured service values with the KTM diagnostics tool. • • • Change the engine oil and filter, clean the oil screen.
  • Page 44 K10A K50A K100A Check the fuel pressure. • • • Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics • • • tool. Check the fluid level of the hydraulic clutch. ( p. 64) •...

  • Page 45: Tuning The Chassis

    TUNING THE CHASSIS Adjusting the compression damping of the 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.

  • Page 46: Adjusting The Spring Preload Of The Fork

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 workshop will be pleased to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 47: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM RC8 workshop will be pleased to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 48: Steering Damper

    TUNING THE CHASSIS – Release lock by pressing in the direction of the arrow and turn handwheel   the way in the LOW direction. – Let go of the lock  – Turn handwheel in the HIGH direction until the handwheel engages. ...

  • Page 49: Vehicle Level

    TUNING THE CHASSIS Vehicle level 9.11 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. The vehicle level can be adjusted at the front by means of the fork leg clamp and at the rear by the eccentric shaft.

  • Page 50: Adjusting The Vehicle Level At The Rear

    TUNING THE CHASSIS – Tighten screw  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 601421-10 – Tighten screw  Guideline Screw, handlebar stub 20 Nm (14.8 lbf ft) –...

  • Page 51: Footrest Position

    TUNING THE CHASSIS Footrest position 9.14 The adjustable footrest system enables an individual setting of the footrest position and an individual adjustment of the controls. The footrest holder can be mounted in 9 different positions on the footrest bracket. The lower footrest position enables a more comfortable knee angle, the upper footrest position a sporting sitting position and more forward-leaning freedom for use in racing.

  • Page 52: Adjusting The Shift Lever

    TUNING THE CHASSIS Adjusting the shift lever 9.17 – Loosen nuts  601431-10 – Turn shift rod while installed until the shift lever is in the desired position.  Guideline ≤ 132 mm (≤ 5.2 in) Shift rod length  Info If the adjustment range of the shift rod is insufficient, the positioning of the shift rod can be changed at the shift lever.

  • Page 53: Adjusting The Foot Brake Lever

    TUNING THE CHASSIS – Position the shift lever stub with the screw into drill hole , or , depending    on the desired lever length. 601435-10 – Tighten screw  Guideline Bolt, foot brake lever stub 10 Nm Loctite ®...

  • Page 54: Adjusting The Handlebar Height

    TUNING THE CHASSIS Adjusting the handlebar height 9.21 Info The handlebar stub position must be identical on the left and right of the vehicle. Adjusting the high position of the handlebar stubs: – Loosen screw  Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub.
  • Page 55 TUNING THE CHASSIS – Remove screw with distance sleeve   – Carefully shift the handlebar stub by the length of the distance sleeve. Guideline Length, distance sleeve 15 mm (0.59 in) – Lay all cables between the upper triple clamp and the handlebar stub. –...

  • Page 56: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the rear of the motorcycle with lifting gear 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the lifting gear at the rear. Adapter (61029055120) Rear wheel stand (61029055400) –...

  • Page 57: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS Bleeding the fork legs 10.5 – Raise the rear of the motorcycle with lifting gear. ( p. 54) – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws.

  • Page 58: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Remove air filter  – Clean the air filter box. 101249-10 Installing the air filter 10.9 – Position air filter  101249-11 – Position the filter box top with the engine breather hose. Mount clamp with the ...

  • Page 59: Removing The Left Side Cover

    SERVICE WORK ON THE CHASSIS » If unoiled areas are visible: – Oil the air filter again. – Wipe off excess filter oil. Info Do not apply too much oil to the air filter. – Install the air filter. p. 56) Removing the left side cover 10.11 –...

  • Page 60: Removing The Exhaust Cover

    SERVICE WORK ON THE CHASSIS Removing the exhaust cover 10.15 – Remove the right side cover. ( p. 57) – Remove the left side cover. ( p. 57) – Unlock quick release  – Repeat the operation on the opposite side. –...

  • Page 61: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws  101244-10 – Clean and disconnect fuel hose connection  Info Remaining fuel may run out of the fuel hose. 101245-10 – Raise the front of the fuel tank. – Detach overflow hose from the T-piece.
  • Page 62 SERVICE WORK ON THE CHASSIS – Position the fuel tank. – Connect electric plug-in connector of the fuel pump.  101247-11 – Position the fuel tank and raise it at the front. – Connect overflow hose  – Lower the front of the fuel tank. 101246-11 –...

  • Page 63: Checking The Fuel Overflow Reservoir

    SERVICE WORK ON THE CHASSIS Checking the fuel overflow reservoir 10.19 – Check the fluid level in the fuel overflow reservoir. » If there is fluid in the fuel overflow reservoir: – Empty the fuel overflow reservoir. ( p. 61) 601453-10 Emptying the fuel overflow reservoir 10.20...

  • Page 64: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 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 ( p.

  • Page 65: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 15… 20 mm (0.59… 0.79 in) Turn adjusting screws on the left and right so that the markings on the left ...

  • Page 66: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS – 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: –...

  • Page 67: Correcting Fluid Level Of Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Correcting fluid level of hydraulic clutch 10.28 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. –...

  • Page 68: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM RC8 workshop will be pleased to help.) – Check the thickness of the brake disc in several places to see if it is within the specified wear tolerance ...

  • Page 69: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 70: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) – Stand the vehicle upright.

  • Page 71: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM RC8 workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 72: Wheels, Tires

    WHEELS, TIRES Removing the front frame sliders 12.1 – Remove screw  – Take off frame slider  – Pull the second frame slider with the linkage arm out of the wheel spindle. 101238-10 Installing the front frame sliders 12.2 –...

  • Page 73: Installing The Front Wheel

    WHEELS, TIRES Installing the front wheel 12.4 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Clean and grease the shaft seal rings and mating surfaces of the spacers.

  • Page 74: Removing The Rear Frame Sliders

    WHEELS, TIRES Removing the rear frame sliders 12.5 – Remove screw  – Take off frame slider  – Pull the second frame slider with the linkage arm out of the wheel spindle. 101263-10 Installing the rear frame sliders 12.6 –...

  • Page 75: Installing The Rear Wheel

    WHEELS, TIRES Installing the rear wheel 12.8 Warning Danger of accidents Reduced braking efficiency 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 accidents No braking effect when operating the rear brake.

  • Page 76: Checking Rear Hub Cush Drive

    Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM RC8 workshop will be pleased to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 77: Checking The Tire Pressure

    WHEELS, TIRES Checking the tire pressure 12.11 Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures riding comfort and maximum tire life. – Remove the dust cap. – Check the tire pressure when the tires are cold. Tire air pressure Front 2.0 bar (29 psi)

  • Page 78: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 79: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 80: Changing The Main Fuse

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

  • Page 81: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM Changing the fuses of individual power consumers 13.5 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. –...

  • Page 82: Cooling System

    COOLING SYSTEM Cooling system 14.1 The water pump with a 3D water pump wheel in the engine ensures forced circula-  tion 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 radiator cap .

  • Page 83: Adding Coolant/Bleeding The Cooling System

    After 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. (Your authorized KTM RC8 workshop will be pleased to help.)
  • Page 84 COOLING SYSTEM – Remove bleeder screws of the cylinder heads.  – Add coolant until it exits from the vent hole without bubbles. Coolant 2.60 l (2.75 qt.) Coolant ( p. 118) Coolant (mixed ready to use) p. 118) – Mount and tighten the bleeder screws with the seal rings.

  • Page 85: Tuning The Engine

    – Move the handlebar to the straight-ahead position. – Throttle position sensor circuit A - check in zero position. Info It is imperative to use the KTM diagnostics tool for this. – Push back protective cover  – Loosen lock nut ...

  • Page 86: Checking/Tuning The Position Of The Quick Shifter

    TUNING THE ENGINE Possible states 0 0 0 A 0 0 B 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 D 401212-10 Shift lever in neutral position ...
  • Page 87 TUNING THE ENGINE – Check the installation position of the quick shifter. Guideline Distance 7… 8 mm (0.28… 0.31 in)  » If the specifications have not been met: – Position the quick shifter. ( p. 86) 601457-10 0 0 0 A 0 0 B 0 0 0 0 0 0 0...

  • Page 88: Positioning The Quick Shifter

    TUNING THE ENGINE Positioning the quick shifter 15.5 – Release nuts while holding quick shifter with your hand.   – Remove screw  601471-10 – Turn heim joint until distance is reached.   Guideline Distance 7… 8 mm (0.28… 0.31 in) ...

  • Page 89: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Remove the left side cover. ( p.

  • Page 90: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE – Remove the exhaust cover. ( p. 58) – Park the motorcycle on a level surface. – Place a suitable container under the engine. – Remove oil drain plug with the magnet, O-rings, and oil screen. ...

  • Page 91: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing.  Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Clean the parts and the sealing area thoroughly. 101221-10 Installing the oil filter 16.5 –...

  • Page 92: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Mount screw  Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 93: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage 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 electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 94: Preparing For Use After Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the rear of the motorcycle with lifting gear. ( p. 54) –...

  • Page 95: Engine Control Blink Code

    ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 09 EFI warning lamp (MIL) flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high Blink code EFI warning lamp (MIL) 13 EFI warning lamp (MIL) flashes 1x long, 3x short...
  • Page 96 ENGINE CONTROL BLINK CODE Blink code EFI warning lamp (MIL) 24 EFI warning lamp (MIL) flashes 2x long, 4x short Error level condition Power supply - circuit fault Blink code EFI warning lamp (MIL) 50 EFI warning lamp (MIL) flashes 5x long Error level condition Motor drive circuit B - circuit fault Blink code EFI warning...

  • Page 97: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled Displacement 1,195 cm³ (72.92 cu in) Stroke 69 mm (2.72 in) Bore 105 mm (4.13 in) Compression ratio 13.5:1 Control DOHC, 4 valves per cylinder, chain-driven Valve - valve stem diameter Intake 42 mm (1.65 in) Exhaust...

  • Page 98: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 19.2 Coolant 2.60 l (2.75 qt.) Coolant ( p. 118) Coolant (mixed ready to use) ( p. 118)

  • Page 99: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Hose clip, intake flange 1.5 Nm (1.11 lbf ft) – Remaining engine screws 6 Nm (4.4 lbf ft) ® Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 3 Nm (2.2 lbf ft) Loctite 243™...
  • Page 100 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) Cylinder head screw M11x1.5 Tightening sequence:...

  • Page 101: Technical Data - Chassis

    10 A Fuse 58011109105 Tires 21.1 Front tire Rear tire 120/70 R 17 TL 200/55 R 17 TL Dunlop Sportmax GP Racer D211 Slick Dunlop Sportmax GP Racer D211 Slick Additional information is available in the Service section under: http://www.ktm.com...

  • Page 102: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Capacity - fuel 21.2 Total fuel tank capacity, 16.5 l (4.36 US gal) Super unleaded (ROZ 100) ( p. 119) approx.

  • Page 103: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 05.18.7E.10 Fork WP Suspension Up Side Down 4354 Compression damping 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 preload - Preload Adjuster...

  • Page 104: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7E.4402 Shock absorber WP Suspension 4618 DACC Compression damping, high-speed Standard 10 clicks Compression damping, low-speed Standard 10 clicks Rebound damping Standard 10 clicks Spring preload Standard 7 mm (0.28 in) Spring rate Medium (standard) 80 N/mm (457 lb/in)

  • Page 105: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining frame bolts 5 Nm (3.7 lbf ft) ® Screw, brake fluid reservoir of rear 5 Nm (3.7 lbf ft) Loctite 243™ brake – Screw, brake line holder 5 Nm (3.7 lbf ft) –...
  • Page 106 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Bolt, front axle M25x1.5 45 Nm (33.2 lbf ft) Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Thread greased – Screw, steering head M25x1.5 18 Nm (13.3 lbf ft)

  • Page 108: Wiring Diagram

    WIRING DIAGRAM Page 1 of 6 25.1 wh-rd rd-bu wh-rd wh-rd wh-rd EM/3 EN/3 wh-rd rd-bu ye-rd ye-rd wh-or ye-rd 101265-01...
  • Page 109 WIRING DIAGRAM Components: Fuse Battery Alternator Starter relay with main fuse Starter motor Combination instrument Diode Emergency OFF switch, electric starter button Voltage regulator...

  • Page 110: 108

    WIRING DIAGRAM Page 2 of 6 25.2 wh-rd wh-or bl-ye wh-rd wh-or bu-gr bu-gr bl-ye bl-bu bl-bu ye-gn bl-or bl-or ye-gn ye-gn ye-gn bl-ye bl-ye wh-rd wh-rd gn-gr gn-gr gn-gr gn-gr 101266-01...
  • Page 111 WIRING DIAGRAM Components: EFI control unit Coolant temperature sensor (cylinder 2) Oil pressure sensor Wheel speed sensor, front Fuse Fuse Power relay Fuel pump relay Fuel pump Combination instrument MODE/LAP button...

  • Page 112: 110

    WIRING DIAGRAM Page 3 of 6 25.3 bl-rd ye-rd bl-rd wh-br wh-pu wh-pu wh-br 101267-01...
  • Page 113 WIRING DIAGRAM Components: EFI control unit Quick shifter control unit Quick shifter Fuse Ignition coil (cylinder 1) Ignition coil (cylinder 2) Quick shifter switch...

  • Page 114: 112

    WIRING DIAGRAM Page 4 of 6 25.4 bl-gr bl-gr bl-bu ye-or ye-or bu-or bu-or gn-or gn-or wh-rd wh-rd bu-pk bu-pk ye-gn ye-gn wh-gn wh-gn br-gr br-gr gn-rd rd-pu rd-pu bl-rd bl-rd gn-rd bl-bu 101268-01...
  • Page 115 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Throttle position sensor circuit B Injector (cylinder 1) Injector (cylinder 2) Motor drive circuit A Motor drive circuit B...

  • Page 116: 114

    WIRING DIAGRAM Page 5 of 6 25.5 br-pu br-pu bl-ye bl-ye wh-bu wh-bu bl-bu bl-bu bl-gn bl-gn wh-bu bl-bu wh-bu wh-bu bl-gn wh-bu bl-bu 101269-01...
  • Page 117 WIRING DIAGRAM Components: EFI control unit Coolant temperature sensor (cylinder 1) Gear position sensor Combination instrument CAN bus terminating resistor Resistance X295 Diagnostics connector...

  • Page 118: 116

    WIRING DIAGRAM Page 6 of 6 25.6 ye-rd ye-rd gn-gr gn-gr bl-bu bl-bu ye-bu ye-bu wh-ye wh-ye 101270-01...
  • Page 119 WIRING DIAGRAM Components: EFI control unit Intake air temperature sensor Ambient air pressure sensor Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Manifold absolute pressure sensor (cylinder 2) X295 Diagnostics connector Cable colors: Black Brown Blue Green Gray Light blue Orange...

  • Page 120: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 121 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...

  • Page 122: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Air filter oil Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Air Filter Oil Spray 655...

  • Page 123: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 124: Index

    INDEX maximum lap speed menu, TOPSPEED ..19, 29-30 INDEX maximum speed menu, LAP/BESTLAP/TopSpeed . . 20, 29-30 Accessories ........5 mode menu, CHANGE MODE .
  • Page 125 INDEX Footrest position ....... 49 installing ....... . . 89 adjusting .
  • Page 126 INDEX Side cover, left installing ....... . . 57 removing ....... . . 57 Side cover, right installing .
  • Page 127 *3211609en* 3211609en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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