KTM 1190 RC8 US 2010 Sport Bike Owner Manual

KTM 1190 RC8 US 2010 Sport Bike Owner Manual
OWNER'S MANUAL 2010
1190 RC8 USA
Art. no. 3211524en
DEAR KTM CUSTOMER
1
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you a great deal of pleasure during your ownership if you service and maintain it accordingly.
DEAR KTM CUSTOMER
We wish you a lot of enjoyment in riding this vehicle.
Please enter the serial numbers of your vehicle below.
Vehicle identification number/type label (
Engine number (
Key number (
p. 26)
Dealer's stamp
p. 27)
p. 26)
The owner's manual contained the latest information for this model at the time of going to print. However, it is never possible to exclude
small deviations arising from further development in design and construction.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not form part of the regular scope of delivery.
DEAR KTM CUSTOMER
© 2009 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
2
TABLE OF CONTENTS
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of labels............................................................. 12
VIEW OF VEHICLE................................................................ 22
View of vehicle, front left side............................................ 22
View of vehicle, rear right side ........................................... 24
LOCATION OF SERIAL NUMBERS ......................................... 26
Vehicle identification number/type label ............................. 26
Key number ..................................................................... 26
Engine number................................................................. 27
Fork part number.............................................................. 27
Shock absorber part number.............................................. 28
Steering damper part number ............................................ 28
CONTROLS .......................................................................... 29
Clutch lever ..................................................................... 29
Hand brake lever .............................................................. 29
Light switch ..................................................................... 30
Headlight flasher switch.................................................... 30
Turn signal switch ............................................................ 31
Horn button ..................................................................... 31
Ignition/steering lock ........................................................ 32
Emergency OFF switch...................................................... 32
Electric starter button ....................................................... 33
immobilizer...................................................................... 33
Combination instrument - overview..................................... 34
Combination instrument - function buttons on handlebar ..... 35
Combination instrument - activation and test ...................... 36
Display ............................................................................ 37
Info display...................................................................... 38
3
Indicator lamps ................................................................
Notes/warnings on the combination instrument....................
Overview of ROAD mode....................................................
Odometer menu ODO/Trip 1 ..............................................
Odometer menu ODO/Trip 2 ..............................................
FUELDISTANCE menu ......................................................
FUELRANGE menu...........................................................
DISTANCE TO Next Service menu ......................................
Overview of RACE mode ....................................................
LAPSTOGO menu .............................................................
TOPSPEED menu .............................................................
LAP/BESTLAP/LastLap menu.............................................
LAP/BESTLAP/TopSpeed menu..........................................
Total distance menu in Race mode RACEODO.....................
Overview of SET‑UP mode .................................................
SET‑UP menu ..................................................................
CHANGE MODE menu ......................................................
SET CLOCK menu ............................................................
SETTINGS menu ..............................................................
SHIFT RPMS menu ..........................................................
LAP menu, LAP BLANK T button .......................................
SET NUM LAPS menu ......................................................
TRIP F RESET menu ........................................................
UNITS menu....................................................................
SET KM/MILES menu .......................................................
SET °C/°F menu ...............................................................
OPTIONS menu................................................................
TPMS menu.....................................................................
OUTERTEMP menu ..........................................................
39
40
44
45
46
47
48
49
50
51
52
53
54
55
56
58
59
60
61
62
63
64
65
66
67
68
69
70
71
TABLE OF CONTENTS
Displaying lap times ......................................................... 76
Displaying maximum speed ............................................... 77
Setting ROAD or RACE mode............................................. 78
Setting the clock with SET CLOCK ..................................... 78
Adjusting shift speed RPM1/2 ........................................... 79
Setting the blank time of the LAP button LAP BLANK T....... 80
Setting the number of laps SET NUM LAPS ........................ 82
Setting the fuel reserve display TRIPF RESET ..................... 83
Setting the kilometers/miles SET KM/MILES ....................... 84
Setting the temperature unit SET °C/°F .............................. 85
Switching the external temperature display on/off ................ 85
Opening the filler cap ....................................................... 87
Closing the filler cap......................................................... 88
Supporting strap............................................................... 88
Seat lock ......................................................................... 89
Helmet lock ..................................................................... 89
Passenger footrests........................................................... 90
Shift lever........................................................................ 90
Foot brake lever................................................................ 91
Side stand ....................................................................... 92
TIPS ON PUTTING INTO OPERATION .................................... 93
Advice on first use ............................................................ 93
Running the engine in....................................................... 94
Loading the vehicle .......................................................... 95
RIDING INSTRUCTIONS ....................................................... 97
checks to be made before putting into operation.................. 97
Starting ........................................................................... 98
Starting up ...................................................................... 99
Shifting, riding ............................................................... 100
4
Braking .........................................................................
Stopping, parking ...........................................................
Refueling.......................................................................
SERVICE SCHEDULE..........................................................
Service schedule ............................................................
MAINTENANCE WORK ON FRAME AND ENGINE..................
Jacking up motorcycle front.............................................
Taking front of motorcycle off work stand..........................
Jacking up motorcycle at the rear.....................................
Taking the rear from the workstand ..................................
Fork/shock absorber ........................................................
Adjusting the compression damping of the fork .................
Adjusting the rebound damping of the fork........................
Adjusting the spring preload of the fork ............................
Bleeding fork legs...........................................................
Compression damping of the shock absorber .....................
Adjusting the low-speed compression damping of the
shock absorber ...............................................................
Adjusting the high-speed compression damping of the
shock absorber ...............................................................
Adjusting the rebound damping of the shock absorber........
Adjusting the spring preload of the shock absorber
.......
Steering damper.............................................................
Adjusting the steering damper .........................................
Vehicle level ..................................................................
Adjusting front vehicle level
........................................
Adjusting the vehicle level at the rear ...............................
Footrest position.............................................................
Adjusting footrest position...............................................
x
x
103
104
105
107
107
110
110
110
111
111
112
112
113
114
115
116
116
117
118
119
121
121
123
124
126
127
127
TABLE OF CONTENTS
5
Adjusting shift lever stub.................................................
Adjusting shift lever........................................................
Adjusting the foot brake lever stub ...................................
Adjusting the foot brake lever ..........................................
Checking free travel of foot brake lever .............................
Checking for chain dirt....................................................
Cleaning the chain..........................................................
Checking the chain tension .............................................
Adjusting the chain tension .............................................
Checking the chain, rear sprocket and engine sprocket.......
Checking the front brake discs.........................................
Checking the rear brake disc............................................
Adjusting the basic position of the hand brake lever...........
Checking the front brake fluid level ..................................
Topping up brake fluid of front brake
...........................
Brake linings..................................................................
Checking the front brake linings.......................................
Checking the rear brake fluid level ...................................
Adding rear brake fluid
..............................................
Checking the rear brake linings ........................................
Removing the front wheel
...........................................
Installing the front wheel
............................................
Removing the rear wheel
............................................
Installing the rear wheel
.............................................
Checking rear hub cush drive
......................................
Checking the tire condition..............................................
Checking the tire pressure ...............................................
Removing the seat ..........................................................
Fitting the seat...............................................................
x
x
x
x
x
x
x
130
130
134
135
135
136
136
138
139
141
143
144
145
145
146
147
148
149
149
151
152
154
156
157
160
160
162
163
163
Removing the passenger seat...........................................
Mounting the passenger seat ...........................................
Mounting the helmet lock on the vehicle...........................
Removing the battery
.................................................
Installing the battery
..................................................
Recharging the battery
...............................................
Changing the main fuse ..................................................
Changing the fuses of individual power consumers.............
Changing the low beam bulb............................................
Changing the high beam bulb ..........................................
Changing the parking light bulb .......................................
Checking the headlight setting.........................................
Adjusting the headlamp range .........................................
Activating/deactivating ignition key ..................................
Cooling system ...............................................................
Checking the coolant level...............................................
Filling the cooling system compensating tank....................
Adjusting basic position of clutch lever.............................
Checking fluid level of hydraulic clutch ............................
Correcting fluid level of hydraulic clutch ...........................
Checking the play in the throttle cable..............................
Adjusting the play in the throttle cable
........................
Handlebar height............................................................
Adjusting the handlebar height ........................................
Rear frame position ........................................................
Adjusting the rear frame position .....................................
Checking the engine oil level ...........................................
Changing engine oil and filter, cleaning oil screen
........
Draining engine oil, cleaning oil screens
......................
x
x
x
x
x
x
164
164
165
165
167
169
171
173
175
178
181
184
184
185
189
189
190
192
192
193
194
195
195
196
198
199
203
204
204
TABLE OF CONTENTS
Removing the oil filter
................................................
Installing the oil filter
................................................
Filling up with engine oil
............................................
Adding engine oil ...........................................................
TROUBLESHOOTING..........................................................
IMMOBILIZER BLINK CODE................................................
ENGINE CONTROL BLINK CODE .........................................
CLEANING.........................................................................
Cleaning motorcycle .......................................................
PROTECTIVE TREATMENT FOR WINTER OPERATION...........
Conservation for winter operation .....................................
STORAGE ..........................................................................
Storage..........................................................................
Putting into operation after storage ..................................
TECHNICAL DATA - ENGINE ...............................................
Capacity - engine oil .......................................................
Capacity - coolant...........................................................
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........
TECHNICAL DATA - CHASSIS .............................................
Lighting equipment ........................................................
Tires .............................................................................
Capacity - fuel................................................................
TECHNICAL DATA - FORK...................................................
TECHNICAL DATA - SHOCK ABSORBER ..............................
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........
SUBSTANCES....................................................................
AUXILIARY SUBSTANCES...................................................
STANDARDS......................................................................
INDEX ...............................................................................
x
x
x
6
207
209
209
211
213
216
218
224
224
226
226
227
227
228
229
230
230
231
234
235
236
236
237
238
240
243
247
249
250
MEANS OF REPRESENTATION
Symbols used
The following explains the meaning of specific symbols.
Identifies an expected reaction (e.g. of an operation or a function).
Identifies an unexpected reaction (e.g. of an operation or a function).
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 handled optimally by specially trained experts with the necessary special tools.
Identifies a page reference (more information is provided on the specified page).
Formats used
The type formats used are explained here.
Specific name
Identifies a name.
Name®
Identifies a protected name.
Brand™
Identifies a trademark.
7
IMPORTANT INFORMATION
8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and race track operation, but not for use
on dirt roads.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for fault-free operation and avoiding premature wear is compliance with the maintenance, care and adjustments to the
engine and chassis described in the owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage and
breakage of components.
Using the motorcycle in extreme conditions such as racing can lead to above-average wear to components such as the power train or
brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period and inspection and maintenance intervals. Close adherence to these periods will
significantly lengthen the service life of your motorcycle.
Warranty
The work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in the service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipulation
and/or other changes to the vehicle.
Materials
The fuels and lubricants named in the owner's manual must be used according to specifications.
Spare parts, accessories
In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM-RC8 workshop. KTM accepts no liability for other products and any resulting damage.
IMPORTANT INFORMATION
9
Some of the spare parts and accessory products are specified in parentheses under the respective descriptions. Your KTM dealer will be
glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
–
Switch off the engine and remove the ignition key.
–
Secure the motorcycle against falling over or running away using straps or other suitable devices.
IMPORTANT INFORMATION
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. To ensure the future of motorcycle sport, make sure you use the motorcycle legally, demonstrate a consciousness for the environment, and respect the rights of others.
10
IMPORTANT INFORMATION
11
IMPORTANT INFORMATION
12
Overview of labels
2.1
700380-11
IMPORTANT INFORMATION
1
Information on putting into operation
2
Type label for Canada
3
Type label for the USA
4
Emission control information
5
Noise emission information
6
Chain tension information
7
Information on suspension setting
8
Fuel evaporative system information
9
Pillion seat locking information (is on the underside of the pillion seat)
Information on putting into operation
600961-01
13
IMPORTANT INFORMATION
14
600932-01
Type label for Canada
600930-01
Type label for the USA
IMPORTANT INFORMATION
15
600959-01
Emission control information
600933-01
Noise emission information
IMPORTANT INFORMATION
16
600928-01
Chain tension information
Information on suspension setting
100486-10
IMPORTANT INFORMATION
Fuel evaporative system information
700387-01
Pillion seat locking information (is on the underside of the pillion seat)
100487-10
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize potential hazards and may therefore be injured.
17
IMPORTANT INFORMATION
18
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–
Be sure to read this owner's manual carefully and completely before taking your first ride. It contains useful information and tips to
help you operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
–
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
IMPORTANT INFORMATION
19
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236; or visit www.nhtsa.dot.gov; or write to:
NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other information about
motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553 x
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1
The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or
2
The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2
Removal or puncturing of any part of the intake system.
3
Lack of proper maintenance.
4
Replacement of any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
IMPORTANT INFORMATION
Operating noise warning
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the
owner may become subject to penalties under state and local ordinances.
Consumer rights
Warranty claims should be submitted to an authorized KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Your rights may vary under national and regional laws.
20
21
VIEW OF VEHICLE
22
View of vehicle, front left side
3.1
700243-10
VIEW OF VEHICLE
1
Clutch lever
2
Light switch, headlight flasher switch, indicator switch, horn button
3
Filler cap
4
Seat
5
Seat lock
6
Oil dipstick
7
Side stand
8
Shift lever
9
Passenger footrests
23
VIEW OF VEHICLE
24
View of vehicle, rear right side
3.2
700242-10
VIEW OF VEHICLE
1
Passenger seat
2
Supporting strap
3
Rear mirror
4
Combination instrument
5
Emergency OFF switch, electric starter button
6
Hand brake lever
7
Chassis number, type label
8
Rear brake caliper
9
Foot brake lever
10
Engine number
11
Brake calipers, front
25
LOCATION OF SERIAL NUMBERS
26
Vehicle identification number/type label
4.1
The vehicle identification number  is stamped on the frame behind the steering head on
the right.
The type label USA  is on the frame above the vehicle identification number.
The type label for Canada is located on the frame on the left behind the steering head.
700231-01
Key number
4.2
The key number Code number  can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
Use the orange programming key to activate and deactivate the black ignition key.
Keep the orange programming key in a safe place: it must only be used for learning
and programming functions.
700222-01
LOCATION OF SERIAL NUMBERS
Engine number
4.3
The engine number  is stamped on the right side of the engine.
700223-01
Fork part number
4.4
The fork part number  is stamped on the inner side of the fork stub.
700224-01
27
LOCATION OF SERIAL NUMBERS
Shock absorber part number
4.5
The shock absorber part number  is stamped on the upper part of the shock absorber
above the adjusting ring towards the rear.
700225-01
Steering damper part number
4.6
The steering damper part number  is stamped on the top of the steering damper.
700226-01
28
CONTROLS
29
Clutch lever
5.1
The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulic and self-adjusting.
700227-01
Hand brake lever
5.2
The hand brake lever  is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
700228-01
CONTROLS
30
Light switch
5.3
The light switch  is fitted on the left side of the handlebar.
Possible states
Low beam on – The light switch is in the lower position. In this position,
the low beam and tail light are switched on.
High beam on – The light switch is in the upper position. In this position,
the low beam, the high beam and the tail light are switched on.
700230-13
Headlight flasher switch
5.4
The headlight flasher switch  is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in neutral position
• Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position.
700232-01
CONTROLS
31
Turn signal switch
5.5
The turn signal switch  is fitted on the left side of the handlebar.
Possible states
Turn signal off
Left turn signal on – The turn signal switch is pressed to the left. The turn
signal switch automatically returns to the central position after use.
Right turn signal on – The turn signal switch is pressed to the right. The
turn signal switch automatically returns to the central position after use.
700230-12
To switch off the turn signal, press the turn signal switch towards the switch housing.
Horn button
5.6
The horn button  is fitted on the left side of the handlebar.
Possible states
• Horn button
• Horn button
700230-11
in neutral position
pressed – The horn is operated in this position.
CONTROLS
32
Ignition/steering lock
5.7
The ignition/steering lock  is located in front of the upper triple clamp.
Info
The ignition may only be switched on using a black ignition key.
Use the orange programming key to activate and deactivate the black ignition key.
Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The black ignition
key can be removed.
700234-01
Ignition ON – In this position, the ignition circuit is closed and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
steering locked. The black ignition key can be removed.
Emergency OFF switch
5.8
The emergency OFF switch  is installed on the right side of the handlebar.
Possible states
Emergency OFF switch on – This position is necessary for operation; the
ignition circuit is closed.
Emergency OFF switch off – In this position, the ignition circuit is
interrupted, a running engine stops, and a non-running engine cannot be
started.
700229-11
CONTROLS
33
Electric starter button
5.9
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button
• Electric starter button
in neutral position
pressed – In this position, the electric starter is operated.
700229-12
immobilizer
5.10
The electronic immobilizer secures the vehicle against unauthorized use.
The immobilizer is activated automatically and the engine electronics are locked when the
ignition key is withdrawn.
The red warning lamp flashes at 15 second intervals after one minute.
The red warning lamp can also indicate errors by flashing.
Info
The ignition key contains electronic components. Never attach multiple ignition keys
to a single key ring; this may cause mutual interference and lead to problems.
400679-10
A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle.
The second black ignition key is activated when the vehicle is shipped.
Two additional spare ignition keys (key number on the KEYCODECARD) can be ordered from
an authorized KTM RC8 workshop, but they must be activated before use.
CONTROLS
34
Combination instrument - overview
5.11
400580-10
1
Display (
p. 37)
2
Function buttons
3
Indicator lamps (
4
Info display (
p. 39)
p. 38)
CONTROLS
35
Combination instrument - function buttons on handlebar
5.12
The MODE button  is fitted on the handlebar, front left.
The LAP button  is fitted on the handlebar, rear left.
MODE button
Changes to the next item on the info display in ROAD mode and in RACE mode.
LAP button
Changes to the next item in the info display in ROAD mode. Clocks the lap times in RACE
mode.
600642-10
CONTROLS
36
Combination instrument - activation and test
5.13
Activation
The combination instrument is activated when the ignition is switched on.
Test
The segments of the tachometer light up in and switch off in sequence.
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.
In RACE mode, the info display switches to LAPSTOGO, LastLap, ±Last, ±Best mode.
400429-10
CONTROLS
37
Display
5.14
The
The
The
The
tachometer  displays the engine speed in revolutions per minute (RPM).
red marking  marks the over-rev (excessive speed) range of the engine.
speed  is displayed in kilometers per hour km/h or in miles per hour Mph.
time appears in segment .
Info
After reconnecting the battery or changing the fuse, the time must be reset.
The coolant temperature is shown in degrees Celsius or Fahrenheit in segment .
The info display  shows additional information.
400580-12
CONTROLS
38
Info display
5.15
The info display  has two menus.
Menu 1 is ROAD mode (standard) for riding on public roads.
Menu 2 is RACE mode for riding on race tracks. It allows riders to time laps themselves.
If the general warning lamp lights up, the corresponding message is shown periodically
in the info display.
Information repeat
45 s
The information shown in the info display can be controlled with the function buttons.
400580-13
CONTROLS
39
Indicator lamps
5.16
Possible states
The turn signal indicator lamp flashes green simultaneously with the turn
signal – The turn signal is switched on.
The oil indicator lamp lights up red – The oil pressure is too low.
The shift warning lights up/flashes red – The set shift speed has been
reached.
The idle speed indicator lamp lights up green – The transmission is shifted
to idle.
The high beam indicator lamp lights up blue – The high beam is switched
on.
EFI warning lamp (MIL) lights up / flashes red – The OBD has detected an
emission- or safety-critical fault.
The general warning lights up yellow – An operating safety (warning) message was detected. This is also shown periodically in the info display.
400580-14
The immobilizer indicator lamp lights up or flashes red – Status or error
message for immobilizer/alarm system.
CONTROLS
40
Notes/warnings on the combination instrument
5.17
LOW FUEL appears on the info display if the minimum range falls below the specified value.
Distance
20 km (12.4 mi)
400476-01
LOW BATTERY appears on the info display if the battery voltage falls below the specified
value.
Battery voltage
400471-01
10.80 V
CONTROLS
41
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 specified
value.
Coolant temperature
120 °C (248 °F)
400474-01
FRONT SENSOR appears on the info display if the front cylinder coolant temperature sensor
is faulty.
400469-01
CONTROLS
42
SENSOR ERROR appears on the info display if the discrepancy between the front and rear
cylinder coolant temperature sensor values differs by more than the specified value.
Coolant temperature
10 °C (50 °F)
400468-01
ICE appears on the info display if the external temperature falls below the specified value.
Temperature
3 °C (37 °F)
ICE disappears if the external temperature rises above the specified value.
Temperature
400467-01
4 °C (39 °F)
CONTROLS
43
CONTROLS
44
Overview of ROAD mode
5.18
400942-10
CONTROLS
45
Functions in ROAD mode
Odometer menu ODO/Trip 1
Odometer menu ODO/Trip 2
FUELDISTANCE menu
FUELRANGE menu
DISTANCE TO Next Service menu
Odometer menu ODO/Trip 1
5.19
Condition
• The ignition is on.
400578-01
•
ROAD Mode
–
Press the MODE button briefly and repeatedly until ODO appears at the top left of the
info display.
ODO shows the total distance covered.
Trip 1 shows the distance covered since the last reset. For example, between two refueling
stops. Trip 1 is always running and counts up to 9999.9.
Time 1 shows the journey time on the basis of Trip 1 and resumes running as soon as a
speed signal is received.
The calculation of this value starts with the first speed signal and ends 3 seconds after the
last speed signal.
Avs 1 (average speed) is coupled with Trip 1 and Time 1.
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
CONTROLS
46
Press the MODE button for 3 - 5 seconds.
The display of Trip 1, Time 1 and Avs 1 is reset
Press the MODE button briefly.
Next display mode
Odometer menu ODO/Trip 2
5.20
Condition
• The ignition is on.
400579-01
•
ROAD Mode
–
Press the MODE button briefly and repeatedly until ODO appears at the top left of the
info display.
ODO shows the total distance covered.
Trip 2 shows the distance covered since the last reset. For example, between two refueling
stops. Trip 2 is always running and counts up to 9999.9.
Time 2 shows the journey time on the basis of Trip 2 and resumes running as soon as a
speed signal is received.
The calculation of this value starts with the first speed signal and ends 3 seconds after the
last speed signal.
Avs 2 (average speed) is coupled with Trip 2 and Time 2.
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
The display of Trip 2, Time 2 and Avs 2 is reset
CONTROLS
47
Press the MODE button briefly.
Next display mode
FUELDISTANCE menu
5.21
Condition
• The ignition is on.
•
ROAD Mode
–
Press the MODE button briefly and repeatedly until FUELDISTANCE appears at the top of
the info display.
TripFuel shows the distance covered since the fuel reserve level was reached.
Info
400441-01
This is displayed only after you reach the fuel reserve level.
OuterTemp shows the external temperature.
The external temperature can be switched on and off in the SET‑UP menu.
Press the button
.
no function
Press the button
.
no function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
no function
Press the MODE button briefly.
Next display mode
CONTROLS
48
FUELRANGE menu
5.22
Condition
• The ignition is on.
•
ROAD Mode
–
Press the MODE button briefly and repeatedly until FUELRANGE appears at the top of the
info display.
TripFuel shows the distance covered since the fuel reserve level was reached.
Info
400577-01
This is displayed only after you reach the fuel reserve level.
MinRange shows the minimum range you can cover with the fuel reserve.
MaxRange shows the maximum range you can cover with the fuel reserve.
The possible range of the fuel reserve depends on your riding style.
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
No function
Press the MODE button briefly.
Next display mode
CONTROLS
49
DISTANCE TO Next Service menu
5.23
Condition
• The ignition is on.
•
The motorcycle is stationary.
•
ROAD Mode
–
Press the MODE button briefly and repeatedly until DISTANCE TO Next Service appears in
the info display.
DISTANCE TO Next Service shows the distance before the next service is necessary.
400443-01
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
No function
Press the MODE button briefly.
Next display mode
CONTROLS
50
Overview of RACE mode
5.24
400943-10
CONTROLS
51
Functions in RACE mode
LAPSTOGO menu
TOPSPEED menu
Lap time LAP/BESTLAP/LastLap menu
Top speed LAP/BESTLAP/TopSpeed menu
Total distance in Race Mode RACEODO menu
LAPSTOGO menu
5.25
Condition
• The ignition is on.
400444-01
•
RACE Mode
–
Press the MODE button briefly and repeatedly until LAPSTOGO appears at the top left of
the info display.
LAPSTOGO shows the number of remaining laps.
If an R appears after LAPSTOGO, the stopwatch is running in the background.
If a P appears after LAPSTOGO, the stopwatch in the background is active but waiting for a
speed signal. The time is not running.
This function is controlled by the button "LAP".
LastLap shows the lap time of the last lap.
±Last shows the difference between the last lap and the lap before last.
±Best shows the difference between the last lap and the best lap.
If the last lap was the fastest, you see behind ±Best: the Best! symbol in the info display.
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
CONTROLS
52
Press the MODE button for 3 - 5 seconds.
All values in RACE mode are reset (except RACEODO)
Press the MODE button briefly.
Next display mode
TOPSPEED menu
5.26
Condition
• The ignition is on.
400445-01
•
RACE Mode
–
Press the MODE button briefly and repeatedly until TOPSPEED appears at the top left of
the info display.
If an R appears after TOPSPEED, the stopwatch is running in the background.
If a P appears after TOPSPEED, the stopwatch is not running in the background.
This function is controlled by the button "LAP".
TOPSPEED shows the highest lap speed.
LastLap shows the maximum speed of the last lap.
±Last shows the maximum speed difference between the last lap and the lap before.
±Best shows the maximum speed difference between the last lap and the highest maximum
speed.
If the last lap was the lap with the highest maximum speed, the info display shows ±Best:
Best!
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
CONTROLS
53
Press the MODE button for 3 - 5 seconds.
The display of LastLap, ±Last and ±Best are set to 0
Press the MODE button briefly.
Next display mode
LAP/BESTLAP/LastLap menu
5.27
Condition
• The ignition is on.
400446-01
•
The motorcycle is stationary.
•
RACE Mode
–
Press the MODE button briefly and repeatedly until LAP/BESTLAP/LastLap appears in the
info display.
LAP shows the selected lap.
BESTLAP shows the number of the lap with the best lap time.
LastLap shows the time of the lap behind LAP.
±Lap shows the difference to the lap before.
±Lap shows the difference to the lap after.
Press the button
.
The next lap is displayed
Press the button
.
The previous lap is displayed
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
All values in RACE mode are reset (except RACEODO)
CONTROLS
54
Press the MODE button briefly.
Next display mode
LAP/BESTLAP/TopSpeed menu
5.28
Condition
• The ignition is on.
400447-01
•
The motorcycle is stationary.
•
RACE Mode
–
Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in
the info display.
LAP shows the selected lap.
BESTLAP shows the lap in which the highest maximum speed was reached.
TopSpeed shows maximum speed of the lap behind LAP.
±Lap shows the difference to the lap before.
±Lap shows the difference to the lap after.
Press the button
.
The next lap is displayed
Press the button
.
The previous lap is displayed
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
All values in RACE mode are reset (except RACEODO)
Press the MODE button briefly.
Next display mode
CONTROLS
55
Total distance menu in Race mode RACEODO
5.29
Condition
• The ignition is on.
400448-01
•
The motorcycle is stationary.
•
RACE Mode
–
Press the MODE button briefly and repeatedly until RACEODO appears at the top of the
info display.
RACEODO shows the total distance covered in RACE mode.
RaceTrip shows the distance covered since the last reset. For example, between two refueling stops. RaceTrip is always running and counts up to 999.9.
MaxRPM shows the highest engine speed reached during the RaceTrip.
TopSpeed shows the highest speed reached during the RaceTrip.
Press the button
.
No function
Press the button
.
No function
Press the button
and the button for
3 - 5 seconds.
The display changes to the SET‑UP menu
Press the MODE button for 3 - 5 seconds.
All values in RACE mode are reset (except RACEODO)
Press the MODE button briefly.
Next display mode
CONTROLS
56
Overview of SET‑UP mode
5.30
400945-01
CONTROLS
Settings in SET‑UP mode
CHANGE MODE menu
SET CLOCK menu
SETTINGS menu
UNITS menu
OPTIONS menu
EXIT SETUP menu
57
CONTROLS
58
SET‑UP menu
5.31
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
and the button
for 3 - 5 seconds.
On the CHANGE MODE menu, you can select between ROAD and RACE mode.
You can set the clock on the SET CLOCK menu.
On the SETTINGS menu, you can set the shift warning light, the lap blank time of the
LAP button, the number of laps, and the reset time of the fuel reserve display.
On the UNITS menu, you can set the units for measuring speed, distance, and temperature.
On the OPTIONS menu, you can switch the tire pressure check and external temperature
display on/off (available as an accessory).
Select EXIT SETUP to close the SET‑UP menu.
The symbol shows which menu you can activate with the button "MODE".
400449-01
Press the button
.
The arrow moves up
Press the button
.
The arrow moves down
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
The menu in front of the arrow is selected
Press the MODE button briefly.
The menu in front of the arrow is selected
CONTROLS
59
CHANGE MODE menu
5.32
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
–
Press the MODE button briefly.
and the button
for 3 - 5 seconds.
On the CHANGE MODE menu, you can select between ROAD and RACE mode.
400475-01
Press the button
.
Changes the menu
Press the button
.
Changes the menu
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit CHANGE MODE
Press the MODE button briefly.
Open and exit CHANGE MODE
CONTROLS
60
SET CLOCK menu
5.33
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
once until the symbol
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows SET CLOCK in the info display.
You can set the clock on the SET CLOCK menu.
400455-01
Press the button
.
Increases the value
Press the button
.
Decreases the value
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit SET CLOCK or change to next value
Press the MODE button briefly.
Open and exit SET CLOCK or change to next value
CONTROLS
61
SETTINGS menu
5.34
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
for 3 - 5 seconds.
appears in front of SETTINGS in the info
On the SHIFT RPMS menu, you can activate the shift warning light.
On the LAP BLANK TIME menu, you can set the lap blank time of the LAP button.
On the SET NUM LAPS menu, you set the number of laps to cover in RACE mode.
On the TRIP F RESET menu, you can set the reaction time of the fuel reserve display to
changes of the fuel level.
On the BACK… menu, you can switch back to the SET‑UP menu.
The symbol shows which menu you can activate with the button "MODE".
400456-01
Press the button
.
The arrow moves up
Press the button
.
The arrow moves down
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
The menu in front of the arrow is selected
Press the MODE button briefly.
The menu in front of the arrow is selected
CONTROLS
62
SHIFT RPMS menu
5.35
Condition
• The ignition is on.
400460-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the MODE button briefly.
for 3 - 5 seconds.
appears in front of SETTINGS in the info
On the SHIFT RPMS menu, you can activate the shift warning light.
Press the button
.
Increases the value
Press the button
.
Decreases the value
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit SHIFT RPMS or change to the next value
Press the MODE button briefly.
Open and exit SHIFT RPMS or change to the next value
CONTROLS
63
LAP menu, LAP BLANK T button
5.36
Condition
• The ignition is on.
400461-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
appears in front of SETTINGS in the info
shows LAP BLANK T in the info display.
On the LAP BLANK T menu, you set the lap blank time of the LAP button.
Press the button
.
Increases the value
Press the button
.
Decreases the value
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit LAP BLANK T
Press the MODE button briefly.
Open and exit LAP BLANK T
CONTROLS
64
SET NUM LAPS menu
5.37
Condition
• The ignition is on.
400462-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
twice until the symbol
appears in front of SETTINGS in the info
shows SET NUM LAPS in the info display.
On the SET NUM LAPS menu, you set the number of laps to cover in RACE mode.
Press the button
.
Increases the value
Press the button
.
Decreases the value
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit SET NUM LAPS
Press the MODE button briefly.
Open and exit SET NUM LAPS
CONTROLS
65
TRIP F RESET menu
5.38
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
play.
–
Press the MODE button briefly.
400463-01
for 3 - 5 seconds.
appears in front of SETTINGS in the info
three times until the symbol
shows TRIP F RESET in the info dis-
On the TRIP F RESET menu, you can set the reaction time of the fuel reserve display to
changes of the fuel level.
Press the button
.
Increases the value
Press the button
.
Decreases the value
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit TRIP F RESET
Press the MODE button briefly.
Open and exit TRIP F RESET
CONTROLS
66
UNITS menu
5.39
Condition
• The ignition is on.
400458-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
three times until the symbol
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows UNITS in the info display.
On the SET KM/MILES menu, you can set the units for measuring speed and distance.
On the SET °C/°F menu, you can set the unit for the temperature display.
On the BACK… menu, you can switch back to the SET‑UP menu.
The symbol shows which menu you can activate with the button "MODE".
Press the button
.
The arrow moves up
Press the button
.
The arrow moves down
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
The menu in front of the arrow is selected
Press the MODE button briefly.
The menu in front of the arrow is selected
CONTROLS
67
SET KM/MILES menu
5.40
Condition
• The ignition is on.
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
three times until the symbol
–
Press the MODE button briefly.
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows UNITS in the info display.
On the SET KM/MILES menu, you can set the units for measuring speed and distance.
400464-01
Press the button
.
Changes the unit
Press the button
.
Changes the unit
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit SET KM/MILES
Press the MODE button briefly.
Open and exit SET KM/MILES
CONTROLS
68
SET °C/°F menu
5.41
Condition
• The ignition is on.
400465-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
three times until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
shows UNITS in the info display.
shows SET °C/°F in the info display.
On the SET °C/°F menu, you can set the unit for the temperature display.
Press the button
.
Changes the unit
Press the button
.
Changes the unit
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit SET °C/°F
Press the MODE button briefly.
Open and exit SET °C/°F
CONTROLS
69
OPTIONS menu
5.42
Condition
• The ignition is on.
400459-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
four times until the symbol
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows OPTIONS in the info display.
On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as an
accessory).
On the OPTION OUTTEMP menu, you can switch the external temperature display on/off.
On the BACK… menu, you can switch back to the SET‑UP menu.
The symbol shows which menu you can activate with the button "MODE".
Press the button
.
The arrow moves up
Press the button
.
The arrow moves down
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
The menu in front of the arrow is selected
Press the MODE button briefly.
The menu in front of the arrow is selected
CONTROLS
70
TPMS menu
5.43
Condition
• The ignition is on.
400478-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
four times until the symbol
–
Press the MODE button briefly.
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows OPTIONS in the info display.
On the OPTION TPMS menu, you can switch the tire pressure check on/off (available as an
accessory).
Press the button
.
Switches the tire pressure display on/off
Press the button
.
Switches the tire pressure display on/off
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit OPTION TPMS
Press the MODE button briefly.
Open and exit OPTION TPMS
CONTROLS
71
OUTERTEMP menu
5.44
Condition
• The ignition is on.
400466-01
•
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
four times until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
shows OPTIONS in the info display.
shows OPTION OUTTEMP in the info display.
On the OPTION OUTTEMP menu, you can switch the external temperature display on/off.
Press the button
.
Switches the external temperature display on/off
Press the button
.
Switches the external temperature display on/off
Press the button
and the button for
3 - 5 seconds.
No function
Press the MODE button for 3 - 5 seconds.
Open and exit OPTION OUTTEMP
Press the MODE button briefly.
Open and exit OPTION OUTTEMP
CONTROLS
72
Table of functions
Display
Press the button
Odometer menu
ODO/Trip 1
No function
Odometer menu
ODO/Trip 2
.
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.
No function
The display
changes to the
SET‑UP menu
The display of
Trip 1, Time 1 and
Avs 1 is reset
Next display mode
No function
No function
The display
changes to the
SET‑UP menu
The display of
Trip 2, Time 2 and
Avs 2 is reset
Next display mode
FUELDISTANCE
menu
no function
no function
The display
changes to the
SET‑UP menu
no function
Next display mode
FUELRANGE menu
No function
No function
The display
changes to the
SET‑UP menu
No function
Next display mode
DISTANCE TO
Next Service menu
No function
No function
The display
changes to the
SET‑UP menu
No function
Next display mode
LAPSTOGO menu
No function
No function
The display
changes to the
SET‑UP menu
All values in
RACE mode are
reset (except
RACEODO)
Next display mode
TOPSPEED menu
No function
No function
The display
changes to the
SET‑UP menu
The display of
LastLap, ±Last and
±Best are set to 0
Next display mode
LAP/BESTLAP/
LastLap menu
The next lap is displayed
The previous lap is
displayed
The display
changes to the
SET‑UP menu
All values in
RACE mode are
reset (except
RACEODO)
Next display mode
CONTROLS
73
Table of functions
Display
Press the button
.
LAP/BESTLAP/
TopSpeed menu
The next lap is displayed
Total distance
menu in Race mode
RACEODO
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.
The previous lap is
displayed
The display
changes to the
SET‑UP menu
All values in
RACE mode are
reset (except
RACEODO)
Next display mode
No function
No function
The display
changes to the
SET‑UP menu
All values in
RACE mode are
reset (except
RACEODO)
Next display mode
SET‑UP menu
The arrow moves up
The arrow moves
down
No function
The menu in front
of the arrow is
selected
The menu in front of the
arrow is selected
CHANGE MODE
menu
Changes the menu
Changes the menu
No function
Open and exit
CHANGE MODE
Open and exit
CHANGE MODE
SET CLOCK menu
Increases the value
Decreases the value
No function
Open and
exit SET CLOCK or
change to next
value
Open and exit SET CLOCK
or change to next value
SETTINGS menu
The arrow moves up
The arrow moves
down
No function
The menu in front
of the arrow is
selected
The menu in front of the
arrow is selected
SHIFT RPMS menu
Increases the value
Decreases the value
No function
Open and exit
SHIFT RPMS or
change to the next
value
Open and exit
SHIFT RPMS or change to
the next value
LAP menu,
LAP BLANK T button
Increases the value
Decreases the value
No function
Open and
exit LAP BLANK T
Open and
exit LAP BLANK T
CONTROLS
74
Table of functions
Display
Press the button
.
SET NUM LAPS
menu
Increases the value
TRIP F RESET menu
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.
Decreases the value
No function
Open and exit
SET NUM LAPS
Open and exit
SET NUM LAPS
Increases the value
Decreases the value
No function
Open and exit
TRIP F RESET
Open and exit
TRIP F RESET
UNITS menu
The arrow moves up
The arrow moves
down
No function
The menu in front
of the arrow is
selected
The menu in front of the
arrow is selected
SET KM/MILES
menu
Changes the unit
Changes the unit
No function
Open and exit
SET KM/MILES
Open and exit
SET KM/MILES
SET °C/°F menu
Changes the unit
Changes the unit
No function
Open and
exit SET °C/°F
Open and exit SET °C/°F
OPTIONS menu
The arrow moves up
The arrow moves
down
No function
The menu in front
of the arrow is
selected
The menu in front of the
arrow is selected
TPMS menu
Switches the tire
pressure display
on/off
Switches the tire
pressure display
on/off
No function
Open and
exit OPTION TPMS
Open and
exit OPTION TPMS
OUTERTEMP menu
Switches the external temperature
display on/off
Switches the external temperature
display on/off
No function
Open and exit
OPTION OUTTEMP
Open and exit OPTION
OUTTEMP
CONTROLS
75
Table of conditions and menu activation
Display
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
ROAD Mode
•
The motorcycle is
stationary.
•
RACE Mode
•
The motorcycle is
stationary.
•
The motorcycle is
stationary.
•
ROAD Mode
•
RACE Mode
Odometer menu ODO/Trip 1
•
Odometer menu ODO/Trip 2
•
FUELDISTANCE menu
•
FUELRANGE menu
•
DISTANCE TO Next Service menu
Menu can be
activated
•
LAPSTOGO menu
•
TOPSPEED menu
•
LAP/BESTLAP/LastLap menu
•
LAP/BESTLAP/TopSpeed menu
•
Total distance menu in
Race mode RACEODO
•
SET‑UP menu
•
CHANGE MODE menu
•
SET CLOCK menu
•
SETTINGS menu
•
SHIFT RPMS menu
•
LAP menu, LAP BLANK T button
•
SET NUM LAPS menu
•
•
CONTROLS
76
Table of conditions and menu activation
Display
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
The ignition is on.
•
ROAD Mode
•
The motorcycle is
stationary.
•
RACE Mode
•
The motorcycle is
stationary.
•
The motorcycle is
stationary.
•
ROAD Mode
•
RACE Mode
Menu can be
activated
TRIP F RESET menu
•
UNITS menu
•
SET KM/MILES menu
•
SET °C/°F menu
•
OPTIONS menu
•
TPMS menu
•
•
OUTERTEMP menu
•
•
Displaying lap times
5.45
Condition
The ignition is on.
The motorcycle is stationary.
RACE Mode
CONTROLS
77
–
Press the MODE button briefly and repeatedly until LAP/BESTLAP/LastLap appears in the
info display.
–
Press the button
–
Press the button
LAP01 appears on the left of the info display.
.
The next lap is displayed.
.
The previous lap is displayed.
400446-01
–
Press the MODE button briefly.
Next display mode
Displaying maximum speed
5.46
Condition
The ignition is on.
The motorcycle is stationary.
RACE Mode
–
Press the MODE button briefly and repeatedly until LAP/BESTLAP/TopSpeed appears in
the info display.
–
Press the button
–
Press the button
LAP01 appears on the left of the info display.
.
The next lap is displayed.
.
The previous lap is displayed.
400447-01
–
Press the MODE button briefly.
Next display mode
CONTROLS
78
Setting ROAD or RACE mode
5.47
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
–
Press the MODE button briefly.
–
Select ROAD mode or RACE mode with the
–
Press the MODE button briefly.
and the button
for 3 - 5 seconds.
The mode set is shown in the info display.
button or the
button.
The settings are stored and the display changes to the SET‑UP menu.
400475-01
–
Press the button
info display.
–
Press the MODE button briefly.
briefly and repeatedly until the symbol
shows EXIT SETUP in the
Setting the clock with SET CLOCK
5.48
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
once until the symbol
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows SET CLOCK in the info display.
The hour is shown.
–
Set the hour with the
–
Press the MODE button briefly.
button or the
button.
The minutes are shown.
400455-01
–
Set the minutes with the
button or the
button.
CONTROLS
79
–
Press the MODE button briefly.
The settings are stored and the display changes to the SET‑UP menu.
–
Press the button
info display.
–
Press the MODE button briefly.
briefly and repeatedly until the symbol
shows EXIT SETUP in the
Adjusting shift speed RPM1/2
5.49
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the MODE button briefly.
for 3 - 5 seconds.
appears in front of SETTINGS in the info
RPM1 and RPM2 appear in the info display.
The engine speed after RPM1 flashes.
Info
400460-01
The engine speed can be set at intervals of 50.
RPM1 is the engine speed above which the shift warning light starts to flash.
–
Set the engine speed with the button
–
Press the MODE button briefly.
or the button
The engine speed after RPM2 flashes.
.
CONTROLS
80
Info
RPM2 is the engine speed above which the shift warning light lights up constantly. If RPM1 = RPM2, the shift warning light lights up constantly when you
reach the engine speed set.
–
Set the engine speed with the button
–
Press the MODE button briefly.
or the button
.
The settings are stored and the display changes to the SETTING menu.
Info
At delivery, RPM1 is set to 10000 and RPM2 to 10500.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
Setting the blank time of the LAP button LAP BLANK T
5.50
Condition
The ignition is on.
The motorcycle is stationary.
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
81
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
appears in front of SETTINGS in the info
shows LAP BLANK T in the info display.
LAP BLANK T. appears in the info display.
Info
400461-01
At delivery, LAP BLANK T. is set to 1 second.
Tip
With LAP BLANK T., 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.
Info
LAP BLANK T. can be set between 1 and 200.
–
Press the MODE button briefly.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
The settings are stored and the display changes to the SETTINGS menu.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
82
Setting the number of laps SET NUM LAPS
5.51
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
twice until the symbol
appears in front of SETTINGS in the info
shows SET NUM LAPS in the info display.
TOTAL LAPS appears in the info display with the number of laps.
Info
400462-01
When delivered, the number of TOTAL LAPS is set to 99 laps.
–
Set the number of laps with the
button or the
button.
Info
You can set TOTAL LAPS to between 1 and 99 laps.
–
Press the MODE button briefly.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
The settings are stored and the display changes to the SETTINGS menu.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
83
Setting the fuel reserve display TRIPF RESET
5.52
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
display.
twice until the symbol
–
Press the MODE button briefly.
–
Press the button
play.
–
Press the MODE button briefly.
for 3 - 5 seconds.
appears in front of SETTINGS in the info
three times until the symbol
shows TRIP F RESET in the info dis-
TRIPF RESET appears in the info display with the reaction time.
400463-01
Info
At delivery, TRIPF RESET is set to 300 seconds.
–
Set the reaction time of the fuel reserve display with the
button or the
button.
Info
You can set the TRIPF RESET to between 10 and 1000 seconds in steps of 10.
–
Press the MODE button briefly.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
The settings are stored and the display changes to the SETTINGS menu.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
84
–
Press the MODE button briefly.
Setting the kilometers/miles SET KM/MILES
5.53
Info
Making a country-specific setting.
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
three times until the symbol
–
Press the MODE button briefly.
–
Press the MODE button briefly.
for 3 - 5 seconds.
shows UNITS in the info display.
The selected unit appears on the left of the display.
400464-01
–
Select the unit with the
–
Press the MODE button briefly.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
button or the
button.
The settings are stored and the display changes to the UNITS menu.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
85
Setting the temperature unit SET °C/°F
5.54
Condition
The ignition is on.
The motorcycle is stationary.
–
Press the button
and the button
–
Press the button
three times until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
shows UNITS in the info display.
shows SET °C/°F in the info display.
The selected unit appears on the left of the display.
400465-01
–
Select the unit with the
–
Press the MODE button briefly.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
button or the
button.
The settings are stored and the display changes to the UNITS menu.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
Switching the external temperature display on/off
5.55
Condition
The ignition is on.
The motorcycle is stationary.
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
86
–
Press the button
and the button
–
Press the button
four times until the symbol
–
Press the MODE button briefly.
–
Press the button
–
Press the MODE button briefly.
–
You can switch the external temperature display on/off with the
ton.
–
Press the MODE button briefly.
for 3 - 5 seconds.
once until the symbol
shows OPTIONS in the info display.
shows OPTION OUTTEMP in the info display.
You see ENABLED or DISABLED in the info display.
400466-01
button or the
but-
The settings are stored and the display changes to the OPTIONS menu.
–
Press the button
display.
–
Press the MODE button briefly.
–
Press the button
info display.
–
Press the MODE button briefly.
briefly and repeatedly until the symbol
briefly and repeatedly until the symbol
shows BACK... in the info
shows EXIT SETUP in the
CONTROLS
87
Opening the filler cap
5.56
–
Lift the cover  of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–
302077-10
To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced.
–
Turn the ignition key 90° clockwise.
–
Open the filler cap.
CONTROLS
88
Closing the filler cap
5.57
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your health.
–
When closing the filler cap, ensure that it is closed correctly. Change clothing that came into contact with fuel. Immediately clean skin that came into
contact with fuel using soap and water.
–
Close the filler cap. Push down the filler cap slightly until the lock closes.
–
Remove the ignition key and close the cover.
700236-01
Supporting strap
5.58
The supporting strap  is provided for the passenger to hold on to.
700244-01
CONTROLS
89
Seat lock
5.59
The seat lock  is behind the seat.
It can be locked with the ignition key.
700245-01
Helmet lock
5.60
The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from
being stolen.
Warning
Danger of accidents Impairment of ride behavior and vehicle operation if a helmet
or helmet lock is attached to the vehicle.
–
700337-01
Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
CONTROLS
90
Passenger footrests
5.61
The passenger footrests can be folded up and down.
Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
700247-01
Shift lever
5.62
The shift lever  is mounted on the left of the engine.
700239-01
CONTROLS
91
The gear positions can be seen in the picture.
The neutral or idle position  is between the first and second gear.
700238-01
Foot brake lever
5.63
The foot brake lever  is in front of the right footrest.
The foot brake lever operates the rear brake.
700237-01
CONTROLS
92
Side stand
5.64
The side stand  is coupled with the safety start system; see the riding instructions.
Possible states
• Side stand folded out – The vehicle can be leaned on the side stand. The safety start
system is active.
• Side stand folded in – This position is mandatory for all journeys. The safety start system is inactive.
700258-01
TIPS ON PUTTING INTO OPERATION
93
Advice on first use
6.1
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
–
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
–
Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
–
New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved
until the tires have been run in.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
TIPS ON PUTTING INTO OPERATION
–
94
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.
–
Before your first trip, read the entire operating instructions carefully.
–
Get to know the controls.
–
Adjust the basic position of clutch lever. (
–
Adjust the basic position of hand brake lever. (
–
Adjust the foot brake lever. (
–
Adjust the shift lever. (
–
Get used to handling the vehicle on suitable terrain before making a longer trip. Try also to ride as slowly as possible to get a better
feeling for the motorcycle.
–
Hold the handlebars firmly with both hands and keep your feet on the footrests when riding.
–
Run the engine in. (
p. 192)
p. 145)
p. 135)
p. 130)
p. 94)
Running the engine in
6.2
–
Do not exceed the specified engine speed and load during the running-in period.
Guideline
Maximum engine speed
–
During the first: 1,000 km (621.4 mi)
7,500 rpm
After the first: 1,000 km (621.4 mi)
10,500 rpm
Avoid full-throttle operation!
TIPS ON PUTTING INTO OPERATION
95
Loading the vehicle
6.3
Warning
Danger of accidents Unstable handling characteristics.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
–
Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
–
Adapt your speed according to your payload. If the motorcycle is loaded with luggage, ride more slowly.
Maximum speed with luggage
130 km/h (80.8 mph)
Warning
Danger of accidents Destruction of luggage carrier system.
–
If the motorcycle is fitted with luggage cases, note the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
–
If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed
properly at regular intervals.
Warning
Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.
–
Adapt your speed according to your payload.
TIPS ON PUTTING INTO OPERATION
96
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
–
If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
–
Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible total weight
380 kg (838 lb.)
Maximum permissible front axle load
150 kg (331 lb.)
Maximum permissible rear axle load
240 kg (529 lb.)
RIDING INSTRUCTIONS
checks to be made before putting into operation
7.1
Info
During operation, the motorcycle must be in a technically perfect condition.
In the interest of riding safety, you should get into the habit of making a general check of the motorcycle before every journey.
–
Check the engine oil level. (
–
Check the engine for oil leaks.
–
Check the fuel level.
–
Check the chain tension. (
–
Clean the chain. (
–
Check the tire condition. (
–
Check the tire pressure. (
–
Check the front brake fluid level. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check the brake system.
–
Check the coolant level. (
–
Check the adjustment and smooth operation of all controls.
–
Check that the electrical equipment is functioning properly.
–
Check that any luggage is fastened correctly.
–
Sit on the motorcycle and check the setting of the rear mirror.
p. 203)
p. 138)
p. 136)
p. 160)
p. 162)
p. 145)
p. 149)
p. 148)
p. 151)
p. 189)
97
RIDING INSTRUCTIONS
Starting
7.2
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 ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–
Always warm up the engine at low engine speeds.
98
RIDING INSTRUCTIONS
99
–
Press the emergency OFF switch into the position
–
Switch on the ignition by turning the black programming key to the position ON
.
.
After you switch on the ignition, you can hear the fuel pump working for about two
seconds. The function test of the combination instrument is run at the same time.
–
Shift into neutral.
–
Press the electric starter button
The green idling speed indicator lamp N  lights up.
.
Info
Do not press the electric starter button until the function test of the combination
instrument is finished.
When starting the engine, DO NOT apply the throttle. If you apply the throttle
during the starting procedure, the engine management shuts off the injectors
and the engine will not start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before
trying again.
This motorcycle is equipped with a safety start system. You can only start the
engine if the transmission is in neutral or if the clutch is pulled when a gear is
engaged. If the side stand is folded down and you shift into gear and release the
clutch, the engine stops.
700248-01
–
Take the weight off the side stand and swing it upwards with your foot as far as it will
go.
Starting up
7.3
–
Pull the clutch lever, shift into first gear, release the clutch slowly and at the same time open the throttle.
RIDING INSTRUCTIONS
100
Shifting, riding
7.4
Warning
Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.
–
Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
–
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
–
Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
–
Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury The passenger must be able to sit securely on the passenger seat.
–
The passenger must hold on to the rider or supporting strap firmly and place his/her feet on the passenger footrests. Observe
the regulations concerning the minimum age for passengers in your country.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
–
Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.
RIDING INSTRUCTIONS
101
Warning
Danger of accidents Reduced road grip with cold tires.
–
On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road
grip is ensured.
Warning
Danger of accidents Reduced road grip with new tires.
–
New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved
until the tires have been run in.
Warning
Danger of accidents Unstable handling characteristics.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
Warning
Danger of accidents Lack of roadworthiness.
–
After a fall, check the vehicle as usual before putting it into operation.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
–
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
RIDING INSTRUCTIONS
102
Note
Engine damage Engine overheating.
–
If the coolant temperature warning lamp lights up, stop the vehicle and switch off the engine. Let the engine cool down, and then
check the coolant level in the radiator and top up if necessary. If you continue your journey with the coolant temperature warning lamp
on, this may cause engine failure.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM-RC8 workshop.
–
When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
–
Release the throttle while simultaneously pulling the clutch lever, shift into the next
gear, release the clutch and open the throttle.
Info
You can see the positions of the six forward gears in the figure. The neutral or
idle position is between the first and second gears. First gear is used for starting
off or for steep inclines.
700238-01
–
After reaching maximum speed by fully opening the throttle, turn the throttle back so it
is ¾ open. This will barely reduce the speed but fuel consumption will be considerably
lower.
–
Accelerate only up to a speed suitable for the road surface and weather conditions.
When traveling in bends, do not shift, and accelerate very carefully.
–
To shift down, brake if necessary and close the throttle at the same time.
–
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open
the throttle or shift again.
–
If the engine stalls (e.g. at a crossroads), pull the clutch lever only and press the starter
button. You do not have to shift into neutral.
RIDING INSTRUCTIONS
103
–
Switch off the engine if you expect to be standing for a long time.
–
If the EFI warning lamp (MIL) starts to light up during the journey, stop immediately. If
you shift to neutral, the EFI warning lamp (MIL) begins to blink.
Info
From the flashing rhythm, you can derive a two-digit number, the so-called blink
code. The flashing code tells you which component has a fault.
Braking
7.5
Warning
Danger of accidents If you brake too hard, the wheels can lock.
–
Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–
Clean or dry dirty or wet brakes by riding and braking gently.
Warning
Danger of accidents Reduced braking effect caused by spongy pressure point of front or rear brake.
–
Have the brake system checked in an authorized KTM-RC8 workshop before continuing your journey.
Warning
Danger of accidents Failure of brake system.
–
If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your
foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
–
Take the longer stopping distance into account when carrying a passenger and baggage.
RIDING INSTRUCTIONS
104
Warning
Danger of accidents Delayed brake action on salted roads.
–
There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the
deposits from the discs by carefully applying the brakes.
–
When braking, first throttle back and then apply the front and rear brakes at the same time.
–
On wet or slippery surfaces, mainly use the rear brake.
–
Braking should always be completed before you enter a bend. Shift down to a lower gear that is appropriate to the vehicle speed.
–
On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You
will require less braking force and the brakes will not overheat.
Stopping, parking
7.6
Warning
Risk of misappropriation Usage by unauthorized persons.
–
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the
vehicle, lock the steering and remove the ignition key.
Warning
Danger of burns Some vehicle components get very hot when the vehicle is in use.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to
cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
RIDING INSTRUCTIONS
–
105
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
–
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand
only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–
Apply the brakes.
–
Shift into neutral.
–
Switch off the ignition by turning the black programming key to the position OFF
.
Info
If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers and the battery is soon discharged. Therefore, always switch off the engine with the
ignition key, the emergency OFF switch is provided for emergency situations only.
–
Park the motorcycle on firm ground.
–
Swing the side stand to the front with your foot as far as it will go, and lean the vehicle onto it.
–
Lock the steering, by turning it to the left, press black ignition key down to position OFF and turn to position
steering lock engagement, move the handlebars gently back and forth. Remove the black ignition key.
. In order to ease
Refueling
7.7
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
RIDING INSTRUCTIONS
106
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
This motorcycle is equipped with a regulated catalytic converter. Leaded fuel will destroy the catalytic converter. You should therefore use unleaded fuel only.
–
Switch off the engine.
–
Open the filler cap. (
–
Fill the fuel tank with fuel up to the lower edge  of the fuel filler.
Total fuel tank
capacity, approx.
–
700321-01
Close the filler cap. (
p. 87)
16.5 l
(4.36 US gal)
p. 88)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 246)
SERVICE SCHEDULE
107
Service schedule
8.1
Check that the electrical equipment is functioning properly.
Read out the trouble code memory using the KTM diagnostics tool.
Change the engine oil and filter, clean the oil screen.
Check the oil jet for the clutch lubrication.
Check the front brake linings. (
x(
x
p. 204)
K10N
K100A
K200A
K400A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
x
p. 148)
•
•
•
•
Check the front brake discs. (
p. 143)
•
•
•
•
Check the rear brake linings. (
p. 151)
•
•
•
•
Check the rear brake disc. (
•
•
•
•
Check that brake lines are undamaged and free of leaks.
p. 144)
•
•
•
•
Check the rear brake fluid level. (
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
p. 149)
Check the free travel of the foot brake lever. (
p. 135)
Check that the shock absorber and fork are leak tight. If necessary and depending on use, service
the fork and shock absorber.
Check the swingarm bearings.
Check wheel bearings for play.
Check the tire condition. (
Check the tire pressure. (
x
x
p. 160)
p. 162)
Check the chain, rear sprocket and engine sprocket. (
Check the chain tension. (
p. 141)
p. 138)
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
x
Clean the dust boots of the fork legs.
Check the front brake fluid level. (
p. 145)
•
SERVICE SCHEDULE
108
K10N
Bleed fork legs. (
p. 115)
Check the steering head bearing play.
•
K100A
K200A
K400A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Change the spark plugs.
x
Check the valve clearance. x
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and
correct routing. x
Drain the drainage hose of the air filter box. x
Check the antifreeze and coolant level.
Check the wiring harness of the throttle valve body for damage and correct routing. x
Check cables for damage and kink-free routing. x
•
Check that the cables are undamaged, routed without sharp bends and set correctly.
•
•
•
•
Check the play in the throttle cable. (
•
•
•
•
•
•
•
•
•
•
•
•
•
p. 194)
Change the air filter. Clean the air filter box.
x
Check the fluid level of the hydraulic clutch. (
Check the screws and nuts for tightness.
Change the coolant.
x
p. 192)
•
•
x
Change the front brake fluid.
x
Change the rear brake fluid. x
Check the clutch. x
•
•
•
•
•
•
SERVICE SCHEDULE
Check the headlight setting. (
109
p. 184)
Check that the radiator fan is functioning properly.
x
Final check: Check the vehicle for roadworthiness and take a test ride.
Read out the fault memory using the KTM diagnostics tool after a test ride.
Make the service entry in KTM DEALER.NET and in the service record.
x
x
K10N: Once after 1,000 km (621.4 mi)
K100A: Every 10,000 km (6,214 mi) or annually
K200A: Every 20,000 km (12,428 mi) or every 2 years or after every sporting use
K400A: Every 40,000 km (24,855 mi) or every 4 years
K10N
K100A
K200A
K400A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
MAINTENANCE WORK ON FRAME AND ENGINE
110
Jacking up motorcycle front
9.1
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Jack up the motorcycle at the rear. (
–
Move the handlebar to the straight-ahead position. Align the work stand at the front
with the adapters to the fork legs.
p. 111)
Front work stand (61029055300)
Info
Always jack up the rear of the motorcycle first.
–
Jack up the motorcycle at the front.
700250-01
Taking front of motorcycle off work stand
9.2
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Secure the motorcycle against falling over.
–
Remove the work stand from the front.
MAINTENANCE WORK ON FRAME AND ENGINE
Jacking up motorcycle at the rear
9.3
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 work stand adapter in the rear of the work stand.
Work stand adapter (61029055120)
Work stand rear (61029055100)
–
Stand the motorcycle upright, align the work stand to the link fork and the adapters,
and jack up the motorcycle.
700251-01
Taking the rear from the workstand
9.4
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Secure the motorcycle against falling over.
–
Remove the work stand from the rear and lean the vehicle on the side stand.
111
MAINTENANCE WORK ON FRAME AND ENGINE
112
Fork/shock absorber
9.5
The fork and the shock absorber offer many options of adapting the chassis to your riding
style and the payload.
Info
To help you adapt the vehicle, we have summarized our findings in Table . You
will find the table on the underside of the seat. In all settings except for the spring
preload of the shock absorber, the value is adjusted by first turning the screw all the
way in and then setting the value. Do not tighten the adjusting screw up against the
stop with force, set the last discernible click as the last position.
700252-01
These adjustments should be understood as a guideline and should always be the basis
of your own personal chassis adaptation. Do not change the adjustments at random or by
more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly
at high speeds.
Adjusting the compression damping of the fork
9.6
Info
The hydraulic compression damping determines the fork suspension behavior.
An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when
the load shifts very fast. It gives the rider good feedback about the road conditions.
MAINTENANCE WORK ON FRAME AND ENGINE
–
113
Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
700253-01
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
Adjusting the rebound damping of the fork
9.7
Info
The hydraulic rebound damping determines the fork suspension behavior.
An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the
zero position.
MAINTENANCE WORK ON FRAME AND ENGINE
–
114
Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
700347-01
Adjusting the spring preload of the fork
9.8
Info
The spring preload defines the initial situation of the spring process of the fork.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus
ensuring an ideal compromise between maneuverability and stability.
MAINTENANCE WORK ON FRAME AND ENGINE
–
115
Turn adjusting screws  clockwise until they are resting against the stop.
Info
The adjustment screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
Comfort
5 turns
Standard
5 turns
Sport
3 turns
Full payload
3 turns
Info
Turn clockwise to increase preload, turn counterclockwise to reduce spring
preload.
Changing the spring preload has no influence on the rebound damping although
the adjusting screws turn during the adjustment work. However, you should also
adjust the rebound damping when you alter the spring preload.
700348-01
Bleeding fork legs
9.9
–
Lean the motorcycle on the side stand.
MAINTENANCE WORK ON FRAME AND ENGINE
–
116
Remove bleeder screws  briefly.
Any excess pressure escapes from the interior of the fork.
–
Mount and tighten bleeder screws.
Info
Perform this action on both fork legs.
700259-01
Compression damping of the shock absorber
9.10
The shock absorber can regulate compression damping separately in the low-speed and
high-speed ranges (Dual Compression Control).
The terms low-speed and high-speed refer to the movement of the shock absorber during
compression and not the riding speed of the motorcycle.
Changes in the low-speed range settings have an impact on the high-speed range and vice
versa.
700340-01
Adjusting the low-speed compression damping of the shock absorber
9.11
Danger
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.)
MAINTENANCE WORK ON FRAME AND ENGINE
117
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
–
Turn adjusting screw  clockwise with a screwdriver up to the last perceptible click.
Info
Do not loosen nut !
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
700255-01
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
Adjusting the high-speed compression damping of the shock absorber
9.12
Danger
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.)
MAINTENANCE WORK ON FRAME AND ENGINE
118
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
–
Turn adjusting screw  clockwise with an open-ended spanner until it stops.
Info
Do not loosen nut !
–
Turn back counterclockwise the number of turns corresponding to the shock absorber
type.
Guideline
Compression damping, high-speed
700256-01
Comfort
3 turns
Standard
2.5 turns
Sport
1.5 turns
Full payload
1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
Adjusting the rebound damping of the shock absorber
9.13
Danger
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.)
MAINTENANCE WORK ON FRAME AND ENGINE
119
–
Turn adjusting screw  clockwise up to the last perceptible click.
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
700257-01
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
10 clicks
Info
Turn clockwise to increase suspension damping; turn counterclockwise to reduce
damping.
Adjusting the spring preload of the shock absorber
9.14
x
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.
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus
ensuring an ideal compromise between maneuverability and stability.
MAINTENANCE WORK ON FRAME AND ENGINE
–
120
Take the weight off the rear wheel and swingarm.
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
–
Loosen screw  two turns, but do not remove.
–
Turn the adjusting ring counterclockwise with the toolset wrench until the spring is
completely relaxed.
700341-10
Hook wrench (69012022000)
Extension (60012060000)
–
Turn the adjusting ring clockwise and tension it to the specified value.
Guideline
Spring preload
700342-01
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 increase preload, turn counterclockwise to reduce spring
preload.
MAINTENANCE WORK ON FRAME AND ENGINE
–
121
Tighten screw .
Guideline
Remaining frame bolts
M5
5 Nm (3.7 lbf ft)
700341-11
Steering damper
9.15
The steering damper suppresses shocks to the steering arising from acceleration on uneven
ground at high speed or when the load is temporarily taken from the front wheel.
The steering damper is adjusted to suit the manner of riding style and the road conditions.
For high speeds, an adjustment with high damping can be chosen in order to use the steering damping function optimally. In slow, tight bends, intensive damping can negatively
affect handling and steering precision, so the damping should be set to low.
700339-01
Adjusting the steering damper
9.16
Info
The hydraulic steering damper stabilizes the steering if the front wheel is raised off the ground or carries no load.
In contrast to other damping elements, the steering damper is adjusted with the damping element open.
MAINTENANCE WORK ON FRAME AND ENGINE
122
–
Turn the adjusting screw  counterclockwise towards "–" as far as the last perceptible
click.
–
Adjust the steering damper according to your riding style and the road conditions by
turning the adjust screw clockwise towards "+".
Guideline
Steering damper adjustment range
1… 32 clicks
Recommended range for use
1… 20 clicks
Standard
1 click
700339-10
Info
Do not change the adjustment of the steering damper during the journey!
After adjusting the steering damper, check the steering for smooth operation,
making sure that the handlebar can be moved from extreme left to extreme right
without a tendency to lock.
MAINTENANCE WORK ON FRAME AND ENGINE
123
Vehicle level
9.17
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.
The fork legs can be clamped at three positions in the triple clamps.
Upper triple clamp flush with
upper edge of fork legs
0 mm (0 in)
Upper triple clamp flush with
1st ring of fork legs
2.5 mm (0.098 in)
Upper triple clamp flush with
2nd ring of fork legs (standard)
5 mm (0.2 in)
The chassis height can be adjusted steplessly by turning the eccentric shaft.
700333-01
Chassis height difference
HIGH - LOW
7 mm (0.28 in)
Maximum adjustment range
between HIGH - LOW
180°
MAINTENANCE WORK ON FRAME AND ENGINE
Adjusting front vehicle level
9.18
124
x
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.
–
Loosen screws  on the lower triple clamp.
–
Loosen screw  on the upper triple clamp.
–
Loosen screw  of the handlebar stub.
Info
Loosen the screws far enough to prevent damage to the lacquer when the fork
legs are moved.
Make the adjustments first on one fork leg and then on the other. When the
screws of both fork legs are loosened, the vehicle sags toward the front.
700352-01
–
Align the fork leg in the desired position by means of the fork rings.
Guideline
700353-01
Upper triple clamp flush with upper edge
of fork legs
0 mm (0 in)
Upper triple clamp flush with 1st ring of
fork legs
2.5 mm (0.098 in)
Upper triple clamp flush with 2nd ring of
fork legs (standard)
5 mm (0.2 in)
MAINTENANCE WORK ON FRAME AND ENGINE
125
Info
The standard adjustment is the setting that provides the best vehicle handling.
When the fork is compressed, the suspension setting changes, causing the vehicle to become more stable but also more difficult to handle.
–
Tighten screw .
Guideline
Screw, top triple clamp
–
M8
17 Nm
(12.5 lbf ft)
M8
15 Nm
(11.1 lbf ft)
M8
20 Nm
(14.8 lbf ft)
Tighten screws .
Guideline
Screw, bottom triple clamp
700352-01
–
Tighten screw .
Guideline
Screw, handlebar stub
–
Repeat the adjustment on the other fork leg.
Info
The vehicle level setting on both fork legs must be identical.
MAINTENANCE WORK ON FRAME AND ENGINE
126
Adjusting the vehicle level at the rear
9.19
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.
–
Loosen screw  but do not remove it.
–
Turn eccentric shaft  to the desired position using the tool from the tool set.
700331-01
Guideline
Standard
LOW
Maximum adjustment range between
HIGH - LOW
180°
Open end wrench SW 38 (69012021000)
700332-01
Info
The chassis height can be adjusted in both directions.
MAINTENANCE WORK ON FRAME AND ENGINE
–
127
Tighten screw .
Guideline
Screw, clamp, eccentric shaft of deflector
M8
18 Nm
(13.3 lbf ft)
700334-01
Footrest position
9.20
The adjustable footrest system enables an individual setting of the footrest height and an
individual adjustment of the controls.
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.
700328-01
Adjusting footrest position
9.21
Info
The footrest position must be identical on the left and the right.
MAINTENANCE WORK ON FRAME AND ENGINE
128
–
Remove screws .
–
Position the footrest bracket with spacers  and screws.
700307-01
Guideline
Standard
Lower position
Info
The adjustable footrest bracket enables a more comfortable lower footrest position or a sporting upper footrest position.
700308-01
–
Mount and tighten screws.
Guideline
Screw, front footrest bracket
700306-01
M8
25 Nm
(18.4 lbf ft)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
700309-01
–
Repeat adjustment work on the footrest bracket on the other side.
–
Adjust the shift lever. (
–
Adjust the foot brake lever. (
p. 130)
p. 135)
129
MAINTENANCE WORK ON FRAME AND ENGINE
130
Adjusting shift lever stub
9.22
–
Remove the screw  with the shift lever stub.
–
Position the shift lever stub with the screw in one of the holes  according to the
desired lever length.
Guideline
Standard
–
Central hole
Tighten screw.
Guideline
Screw, shift lever stub
M6
10 Nm
(7.4 lbf ft)
700304-01
Adjusting shift lever
9.23
Info
The footrest system offers many ways of adjusting the shift lever to your riding style and requirements.
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
131
–
Remove screws  and take off the shift rod.
–
The length of the shift rod can be adjusted by means of the screw thread.
Guideline
Shift rod
–
Loosen the counter nuts .
–
Adjust the shift shaft.
115… 130 mm (4.53… 5.12 in)
Info
Make the same adjustments on both sides.
After the counter nuts have been tightened, the bearings of the shift shaft must
be central and aligned identically to each other in order to ensure freedom of
movement in the bearing shells.
At least 5 screw threads must be screwed into the seating.
–
700343-01
Tighten the counter nuts.
MAINTENANCE WORK ON FRAME AND ENGINE
–
132
The shift rod can be mounted both on the shift lever variably at an upper or lower position, and on the reverse gear change of the shift shaft in two different positions.
Guideline
A
0
B
0
Standard 
shift lever: lower drill hole,
shift shaft: lower drill hole
Shift power low, long shift travel 
shift lever: lower drill hole,
shift shaft: upper drill hole
Shift power high, short shift travel 
shift lever: upper drill hole,
shift shaft: lower drill hole
–
Position the shift rod.
–
Tighten the screws.
Guideline
Screw, shift rod
C
0
400479-10
M6
12 Nm
(8.9 lbf ft)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
–
133
The position of the shift lever can be greatly varied, depending on the length of the shift
rod and the drill holes selected. As seen from the footrest, there is either a high position
of the shift lever  or a low position of the shift lever .
Info
If you turn the reverse shift shaft 2 teeth on the serration of the shift shaft, you
can adjust the footrest system optimally for the upper footrest position.
–
After adjusting the shift lever, check its operation. There must be a minimum distance
between the moving parts of the shift lever and other parts of the vehicle.
Guideline
Minimum clearance
700344-01
5 mm (0.2 in)
MAINTENANCE WORK ON FRAME AND ENGINE
134
Adjusting the foot brake lever stub
9.24
–
Remove the screw  with the foot brake lever stub.
–
Position the foot brake lever stub with the screw in one of the holes  according to the
desired lever length.
Guideline
Standard
–
Central hole
Tighten the screw.
Guideline
Bolt, foot brake lever stub
700305-01
M6
10 Nm
(7.4 lbf ft)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
135
Adjusting the foot brake lever
9.25
–
Use the tool to press in the anti-rotation lock , then turn the piston rod .
Info
The range of adjustment is limited.
–
Remove the tool.
The spring tension on the anti-rotation lock is released and the hex nut is locked.
700345-01
–
Check the foot brake lever setting.
Info
Position  of the foot brake lever may vary considerably, depending on the setting.
700346-01
Checking free travel of foot brake lever
9.26
Warning
Danger of accidents Brake system failure.
–
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications.
MAINTENANCE WORK ON FRAME AND ENGINE
–
136
Move the foot brake lever back and forth between the end stop and the contact to the
foot brake cylinder piston and check free travel .
Guideline
Free travel at foot brake lever
3… 5 mm (0.12… 0.2 in)
Info
The piston rod should not move in the process.
»
700237-10
If the free travel does not meet specifications:
–
Adjust the free travel.
Checking for chain dirt
9.27
–
Check the chain for loose dirt.
»
If the chain is very dirty:
–
Clean the chain. (
400678-01
Cleaning the chain
9.28
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
–
Remove oil and grease with a suitable cleaning material.
p. 136)
MAINTENANCE WORK ON FRAME AND ENGINE
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
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
–
Clean the chain regularly.
–
Rinse off loose dirt with a soft jet of water.
–
Remove old grease remains with chain cleaner.
Chain cleaner (
–
p. 247)
After drying, apply chain spray.
Chain lube for road use (
400725-01
p. 247)
137
MAINTENANCE WORK ON FRAME AND ENGINE
138
Checking the chain tension
9.29
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
–
Lean the motorcycle on the side stand.
–
Shift into neutral.
–
In the area in front of where the chain passes through the link fork, push the chain
upward and measure chain tension .
Info
The lower chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
700322-01
Chain tension
»
15… 20 mm (0.59… 0.79 in)
If the chain tension does not meet specifications:
–
Adjust the chain tension. (
p. 139)
MAINTENANCE WORK ON FRAME AND ENGINE
139
Adjusting the chain tension
9.30
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
–
Check the chain tension. (
p. 138)
MAINTENANCE WORK ON FRAME AND ENGINE
140
–
Loosen nut .
–
Loosen nuts .
–
Adjust chain tension by turning the adjustment screws  on the left and right.
Guideline
Chain tension
15… 20 mm (0.59… 0.79 in)
Turn the adjusting screws  on the left and right so that the markings on the left and
right chain adjuster  are in the same position in relation to the reference marks .
The rear wheel is then correctly aligned.
Info
The lower chain section must be taut.
Chain wear is not always even, so you should check the setting at different chain
positions.
–
Tighten nuts .
–
Make sure that the chain adjusters  are on the adjusting screws .
–
Tighten nut .
Guideline
700323-01
Nut, rear wheel spindle
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Info
The wide adjustment range of the chain adjuster (35mm / 1.38") allows different secondary transmission ratios to be used with the same chain length.
The chain adjusters  can be turned through 180°.
MAINTENANCE WORK ON FRAME AND ENGINE
141
Checking the chain, rear sprocket and engine sprocket
9.31
–
Check the rear sprocket and engine sprocket for wear.
»
If the rear sprocket and engine sprocket are worn:
–
Replace the rear sprocket or engine sprocket.
x
Info
The engine sprocket, rear sprocket and chain should always be replaced
together.
100132-10
MAINTENANCE WORK ON FRAME AND ENGINE
–
142
Shift into neutral, and pull the lower chain section with the specified weight .
Guideline
Weight, chain wear measurement
–
15 kg (33 lb.)
Measure the distance  of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Maximum distance  at the longest
chain section
»
272 mm (10.71 in)
If distance  is greater than the specified measurement:
–
Replace the chain.
x
Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
A new chain wears out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint.
700303-01
–
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:
–
–
»
If the chain sliding guard is loose:
–
700351-11
Change the chain sliding guard.
x
Check that the chain sliding guard is firmly seated.
Tighten the chain sliding guard.
MAINTENANCE WORK ON FRAME AND ENGINE
143
Guideline
Remaining chassis screws
M6
10 Nm
(7.4 lbf ft)
Checking the front brake discs
9.32
Warning
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 .
Info
Wear reduces the thickness of the brake discs in area  of the brake discs.
Brake discs - wear limit
Front
»
100135-10
If the brake disc thickness is less than the specified value:
–
–
4.0 mm (0.157 in)
Change the brake discs.
x
Check the brake discs for damage, cracking and deformation.
»
If the brake discs exhibit damage, cracking or deformation:
–
Change the brake discs.
x
MAINTENANCE WORK ON FRAME AND ENGINE
144
Checking the rear brake disc
9.33
Warning
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 conforms to measurement .
Info
Wear reduces the thickness of the brake disc in area  of the brake disc.
Brake disc - wear limit
Rear
»
400480-10
If the brake disc thickness is less than the specified value:
–
–
4.5 mm (0.177 in)
Change the brake disc.
x
Check the brake disc for damage, cracking and deformation.
»
If damage, cracks or deformation are visible on the brake disc:
–
Change the brake disc.
x
MAINTENANCE WORK ON FRAME AND ENGINE
145
Adjusting the basic position of the hand brake lever
9.34
–
Pull the brake lever forwards.
–
Adjust the basic setting of the hand brake lever to your hand size by turning adjusting
wheel .
Info
Do not make any adjustments while riding!
700260-01
Checking the front brake fluid level
9.35
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM RC8 workshop will be pleased to help.)
Warning
Danger of accidents Reduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will
be pleased to help.)
MAINTENANCE WORK ON FRAME AND ENGINE
146
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in the brake fluid reservoir .
»
If the brake fluid is below the MIN marking:
–
Top up the brake fluid of the front brake.
x(
p. 146)
700261-01
Topping up brake fluid of front brake
9.36
x
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM RC8 workshop will be pleased to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidents Reduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will
be pleased to help.)
MAINTENANCE WORK ON FRAME AND ENGINE
147
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake
fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.
Use only clean brake fluid from a sealed container!
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Loosen screw.
–
Remove cap  with membrane .
–
Add brake fluid to the MAX level.
Brake fluid DOT 4 / DOT 5.1 (
–
700262-01
p. 243)
Position the cap with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
Brake linings
9.37
The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the
brake linings are entered in the homologation documents.
MAINTENANCE WORK ON FRAME AND ENGINE
148
Info
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and
friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If
brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle
no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Checking the front brake linings
9.38
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM RC8 workshop will be pleased to help.)
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.
–
Check all brake linings on both brake calipers to ensure they have minimum thickness .
≥ 1 mm (≥ 0.04 in)
Minimum thickness 
»
If the minimum thickness is less than specified:
–
–
»
700263-01
Change the front brake linings.
x
Check all brake linings on both brake calipers for damage and cracking.
If damage or wear is encountered:
–
Change the front brake linings.
x
MAINTENANCE WORK ON FRAME AND ENGINE
149
Checking the rear brake fluid level
9.39
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM RC8 workshop will be pleased to help.)
Warning
Danger of accidents Reduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will
be pleased to help.)
–
Stand the vehicle upright.
–
Check the brake fluid level of the brake fluid reservoir.
»
If the fluid level reaches the MIN mark :
–
Add rear brake fluid.
x(
p. 149)
700264-01
Adding rear brake fluid
9.40
x
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM RC8 workshop will be pleased to help.)
MAINTENANCE WORK ON FRAME AND ENGINE
150
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidents Reduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM RC8 workshop will
be pleased to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake
fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive and will damage painted surfaces.
Use only clean brake fluid from a sealed container!
MAINTENANCE WORK ON FRAME AND ENGINE
–
Stand the vehicle upright.
–
Remove screw cap  with membrane .
–
Add brake fluid to the MAX level.
Brake fluid DOT 4 / DOT 5.1 (
–
p. 243)
Refit screw with membrane.
Info
700265-01
Clean up overflowed or spilt brake fluid immediately with water.
Checking the rear brake linings
9.41
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM RC8 workshop will be pleased to help.)
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.
151
MAINTENANCE WORK ON FRAME AND ENGINE
–
152
Check the brake linings for minimum thickness .
≥ 1 mm (≥ 0.04 in)
Minimum thickness 
»
If the minimum thickness is less than specified:
–
–
Change the rear brake linings.
x
Check the brake linings for damage and cracking.
»
If damage or wear is encountered:
–
Change the rear brake linings.
x
700266-01
Removing the front wheel
9.42
x
–
Jack up the motorcycle at the rear. (
–
Jack up the motorcycle at the front. (
–
Remove the screws  from both brake calipers.
–
Press back the brake linings with a light lateral tilting of the brake calipers on the brake
disc. Pull the brake calipers carefully back from the brake discs and hang them to one
side.
p. 111)
p. 110)
Info
Do not pull the hand brake lever when the brake calipers are removed.
700271-10
MAINTENANCE WORK ON FRAME AND ENGINE
153
–
Loosen screws  and .
–
Unscrew screw  about six turns and press your hand on the screw to push the wheel
spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
discs.
–
700272-10
301443-12
Always lay the wheel down in such a way that the brake discs are not damaged.
–
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the
fork.
–
Remove spacers .
MAINTENANCE WORK ON FRAME AND ENGINE
Installing the front wheel
9.43
154
x
–
Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Replace the wheel bearing.
x
Clean and grease the shaft seal rings  and mating surfaces  of the spacers.
Long-life grease (
p. 247)
301443-10
–
Insert the wide spacer on the left-hand side  (when looking in the direction of travel).
Info
The arrow  indicates the direction of rotation of the front wheel.
–
301444-10
Insert the narrow spacer on the right-hand side (when viewed in the direction of travel).
MAINTENANCE WORK ON FRAME AND ENGINE
155
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–
200487-10
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–
Clean screw  and axle .
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
–
Mount and tighten screw .
Guideline
Bolt, front axle
M25x1.5
45 Nm
(33.2 lbf ft)
–
Position the brake calipers and check that the brake linings are seated correctly.
–
Mount screws  on both brake calipers but do not tighten yet.
–
Operate the hand brake lever repeatedly until the brake lining presses up against the
brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
The brake calipers align themselves.
–
Tighten screws  on both brake calipers.
Guideline
700271-12
Screw, front brake caliper
M10x1.25
45 Nm
(33.2 lbf ft)
–
Release the fixation of the hand brake lever.
–
Take the front of the motorcycle off the work stand. (
–
Take the rear from the work stand. (
p. 111)
p. 110)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
–
156
Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
–
Fully tighten screws .
Guideline
Fork end pinch bolts
M8
700272-11
Removing the rear wheel
9.44
x
700311-01
–
Jack up the motorcycle at the rear. (
–
Remove nut .
–
Remove chain adjuster .
–
Remove the axle .
p. 111)
15 Nm
(11.1 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
–
157
Push the rear wheel as far forward as possible and then remove the chain from the rear
sprocket.
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
discs.
–
301453-10
–
Always lay the wheel down in such a way that the brake discs are not damaged.
Take the rear wheel out of the swingarm carefully without damaging the rim or brake
disc.
Info
Do not operate the foot brake when the rear wheel is removed.
Installing the rear wheel
9.45
x
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.
–
After installing the rear wheel, always operate the foot brake until the pressure point is reached.
–
Check the rear hub cush drive.
x(
p. 160)
MAINTENANCE WORK ON FRAME AND ENGINE
–
Remove spacer . Clean and grease the mating surfaces of the spacers and the shaft
seal rings.
Long-life grease (
–
If the wheel bearing is damaged or worn:
–
700314-01
p. 247)
Check the wheel bearing for damage and wear.
»
700313-10
158
Replace the wheel bearing.
x
–
Install the spacer.
–
Clean the thread of the axle and nut.
–
Clean the mating surfaces of the brake caliper frame and swingarm.
–
Push the brake caliper frame  completely to the rear.
–
Position the rear wheel, and place the brake caliper frame between the rim and the
brake disc.
–
Slide the brake caliper onto the brake disc.
–
Position the rear wheel on the mating surfaces in the swingarm.
MAINTENANCE WORK ON FRAME AND ENGINE
159
–
Push the rear wheel as far forward as possible and place the chain on the rear sprocket.
–
Pull the rear wheel back and insert the axle.
–
Place the chain adjuster  on the tensioning screw.
–
Position the chain adjuster  and place it on the tensioning screw.
–
Tighten nut .
700315-01
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and right
chain adjusters must be in the same position relative to the reference marks .
Nut, rear wheel spindle
700316-01
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
–
Operate the foot brake lever repeatedly until the brake linings press up against the
brake disc and there is a pressure point.
–
Take the rear from the work stand. (
–
Check the chain tension. (
p. 138)
p. 111)
MAINTENANCE WORK ON FRAME AND ENGINE
Checking rear hub cush drive
9.46
160
x
Info
The engine power is transmitted by the rear sprocket to the rear wheel through five shock absorbers. They eventually wear out during operation. If the shock absorbers are not changed in time, the rear sprocket carrier and the rear hub are damaged.
–
Remove the rear wheel.
–
Remove the rear sprocket carrier.
–
Check the rear hub for damage and wear.
»
p. 156)
If the rear hub cush drive is damaged or worn:
–
–
x(
Change the shock absorber.
x
Position the rear sprocket carrier.
Info
A set of bolts and shock absorbers should have as little free play as possible to
increase the service life of the shock absorbers.
700274-01
–
Install the rear wheel.
x(
p. 157)
Checking the tire condition
9.47
Warning
Danger of accidents Uncontrollable handling characteristic caused by a flat tire.
–
For your own safety, have damaged tires changed immediately.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
MAINTENANCE WORK ON FRAME AND ENGINE
161
Warning
Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
–
Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
–
New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved
until the tires have been run in.
Info
The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
–
Check the front and rear tires for cuts, run-in objects and other damage.
»
If the tires exhibit cuts, run-in objects or other damage:
–
–
Change the tires.
Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
400602-10
»
If the tread depth is less than the minimum permissible depth:
–
–
≥ 2 mm (≥ 0.08 in)
Change the tires.
Check the age of the tires.
MAINTENANCE WORK ON FRAME AND ENGINE
162
Info
The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the
week of manufacture and last two digits refer to the year of manufacture.
KTM recommends that the tires are changed regardless of the actual wear, at
the latest after five years.
»
If a tire is more than five years old:
–
Change the tires.
Checking the tire pressure
9.48
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure tool kit comfort and maximum tire service life.
–
Remove the dust cap.
–
Check the tire pressure when the tires are cold.
Tire air pressure, solo
Front
2.5 bar (36 psi)
Rear
2.5 bar (36 psi)
Tire air pressure with passenger / full payload
400695-01
»
Front
2.5 bar (36 psi)
Rear
2.9 bar (42 psi)
If the tire pressure does not meet specifications:
–
Correct the tire pressure.
MAINTENANCE WORK ON FRAME AND ENGINE
–
163
Mount the dust cap.
Info
The rubber seal in the dust cap prevents air leaking out of the tire if the valve is
defective.
Removing the seat
9.49
–
Insert the ignition key in the seat lock  and turn it clockwise.
–
Raise the rear of the seat, push it towards the rear, and remove it upwards.
–
Position the recesses of the seat to the lugs on the frame, lower the rear end and simultaneously push it forward.
–
Lock the seat by turning the ignition key in the seat lock.
–
Remove the ignition key from the seat lock.
–
Finally, check that the seat is correctly mounted.
700245-01
Fitting the seat
9.50
700269-01
MAINTENANCE WORK ON FRAME AND ENGINE
164
Removing the passenger seat
9.51
–
Remove the seat. (
–
Activate the release lever .
–
Take off the passenger seat  toward the top.
p. 163)
700246-01
Mounting the passenger seat
9.52
Warning
Danger of accidents The passenger seat can come loose from the anchoring if it
is not mounted correctly.
–
700275-01
After mounting the passenger seat, check that it is locked correctly by
pulling up on the supporting strap. There should be no play in the unlocking
lever.
–
Position the passenger seat in the space provided.
–
Press down the passenger seat until it clicks into place.
–
Finally, check that the passenger seat is correctly mounted.
MAINTENANCE WORK ON FRAME AND ENGINE
165
Mounting the helmet lock on the vehicle
9.53
Warning
Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.
–
Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
–
Remove the seat. (
–
Position the steel cable from the tool kit with one loop on the lug .
p. 163)
Steel cable (60012015000)
–
Guide the steel cable through the helmet opening.
–
Then position the free loop of the steel cable on the lug.
–
Position the helmet carefully on the side of the vehicle.
–
Fit the seat. (
p. 163)
700336-01
Removing the battery
9.54
x
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a doctor.
MAINTENANCE WORK ON FRAME AND ENGINE
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
–
Switch off all power consumers and the engine.
–
Remove the seat. (
–
Disconnect negative (minus) cable  of the battery.
–
Remove the cover of the positive terminal.
–
Disconnect the positive (plus) cable  of the battery.
p. 163)
700276-10
700277-10
166
MAINTENANCE WORK ON FRAME AND ENGINE
–
Remove screws .
–
Removing the securing bracket .
–
Pull the battery up and out of the battery rack.
–
Position the battery in the battery rack.
700278-01
Installing the battery
9.55
x
Info
The terminals of the battery must face the rear of the vehicle.
–
700279-01
Position the bracket .
167
MAINTENANCE WORK ON FRAME AND ENGINE
–
168
Mount and tighten screws .
Guideline
Remaining chassis screws
M6
–
Reconnect the positive (plus)  cable of the battery.
–
Position cover of the positive terminal.
–
Reconnect the negative (minus) cable  of the battery.
–
Fit the seat. (
–
Set the clock with SET CLOCK. (
700277-11
700276-11
p. 163)
p. 78)
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
Recharging the battery
9.56
169
x
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a doctor.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
–
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.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
MAINTENANCE WORK ON FRAME AND ENGINE
170
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–
Switch off all power-consuming components and switch off the engine.
–
Remove the seat. (
–
Disconnect the negative (minus) cable of the battery to avoid damage to the motorcycle's electronics.
p. 163)
MAINTENANCE WORK ON FRAME AND ENGINE
–
171
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.
Info
Never remove lid .
Charge the battery at no more than 10% of the capacity specified on the battery
housing .
–
Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
–
Fit the seat. (
–
Set the clock with SET CLOCK. (
p. 163)
p. 78)
100151-10
Changing the main fuse
9.57
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
–
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
3 months
MAINTENANCE WORK ON FRAME AND ENGINE
Info
The main fuse protects all power consumers of the vehicle. The main fuse is under the seat.
–
Switch off all power consumers and the engine.
–
Remove the seat. (
–
Remove protection covers .
–
Remove the faulty main fuse .
p. 163)
Info
A reserve fuse  is located in the starter relay.
–
Install a new main fuse.
Fuse (58011109130) (
p. 235)
Tip
Place the spare fuse in the starter relay so that it is available if needed.
700280-01
–
Attach the protection covers .
–
Fit the seat. (
–
Set the clock with SET CLOCK. (
p. 163)
p. 78)
172
MAINTENANCE WORK ON FRAME AND ENGINE
Changing the fuses of individual power consumers
9.58
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
–
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.
700281-01
–
Switch off all power consumers and the engine.
–
Remove the seat. (
–
Open fuse box cover .
p. 163)
173
MAINTENANCE WORK ON FRAME AND ENGINE
–
Check the fuses.
Info
A defective fuse can be identified by the burned-out fuse wire .
–
Remove the faulty fuse.
Guideline
Fuse 1 - 10A - ignition, combination instrument, immobilizer, alarm system
(optional)
700282-01
Fuse 2 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 3 - 10A - horn, brake light
Fuse 4 - 10A - radiator fan
Fuse 5 - 10A - fuel pump
Fuse 6 - 10A - ignition/fuel injection
Fuse 7 - not used
Fuse 8 - 10A - for supplementary equipment (standard accessories)
Fuse 9 - 10A - for supplementary equipment (accessories connected to the ignition
switch)
Fuse 10 - not used
Fuse SPARE - 10A/15A - spare fuses
–
Use spare fuses with the correct rating only.
Fuse (75011088010) (
p. 235)
Fuse (75011088015) (
p. 235)
Tip
Replace the spare fuse in the fuse box so that it is available if needed.
174
MAINTENANCE WORK ON FRAME AND ENGINE
–
Close the fuse box cover.
–
Fit the seat. (
175
p. 163)
Changing the low beam bulb
9.59
Note
Damage to reflector Reduced luminance.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
700293-01
–
Switch off all power consumers and the engine.
–
Fold up the combination instrument. Pull the lug  out of the rubber retainer .
–
Remove the rubber retainer.
MAINTENANCE WORK ON FRAME AND ENGINE
176
–
Release the latch .
–
Remove the lamp cover .
–
Disconnect plug-in connector .
–
Push off the retaining clamp  on both sides, squeeze and fold to the side.
–
Remove headlight bulb .
–
Position the new headlight bulb in the headlight housing.
700294-01
700295-01
Low beam / high beam (H7 / base PX26d) (
p. 235)
Info
Insert the headlight bulb so that the lug  is positioned in the cut-out.
700296-01
–
Position the retaining clamp.
–
Position the plug-in connector.
MAINTENANCE WORK ON FRAME AND ENGINE
–
Position the lug  of the lamp cover in the notch. Engage the latch .
–
Check that the lighting is functioning properly.
–
Position the rubber holder .
–
Fold down the combination instrument. Position the lug  in the rubber retainer.
400422-10
700293-11
177
MAINTENANCE WORK ON FRAME AND ENGINE
178
Changing the high beam bulb
9.60
Note
Damage to reflector Reduced luminance.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
700297-01
–
Switch off all power consumers and the engine.
–
Remove screws . Remove the cover.
MAINTENANCE WORK ON FRAME AND ENGINE
179
–
Release the latch .
–
Remove the lamp cover .
–
Disconnect plug-in connector .
–
Push off the retaining clamp  on both sides, squeeze and fold to the side.
–
Remove headlight bulb.
–
Position the new headlight bulb in the headlight housing.
700298-01
Low beam / high beam (H7 / base PX26d) (
p. 235)
Info
Insert the headlight bulb so that the lug is positioned in the cut-out.
700299-01
–
Position the retaining clamp.
–
Position the plug-in connector.
MAINTENANCE WORK ON FRAME AND ENGINE
180
–
Position the lug  of the lamp cover in the notch. Engage the latch.
–
Check that the lighting is functioning properly.
–
Position the cover.
400422-11
Info
Check for correct positioning and freedom of movement of the brake lines.
–
Mount and tighten screws .
Guideline
Remaining chassis screws
700335-10
M6
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
181
Changing the parking light bulb
9.61
Note
Damage to reflector Reduced luminance.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
700297-01
–
Switch off all power consumers and the engine.
–
Remove screws . Remove the cover.
MAINTENANCE WORK ON FRAME AND ENGINE
182
–
Release the latch .
–
Remove the lamp cover .
–
Pull the parking light  carefully out of the holder.
–
Remove the light bulb.
–
Position a new light bulb in the holder.
700298-01
Parking light (W5W / base W2.1x9.5d) (
–
700300-01
p. 235)
Carefully position the holder with the bulb in the holder in the headlight.
MAINTENANCE WORK ON FRAME AND ENGINE
183
–
Position the lug  of the lamp cover in the notch. Engage the latch.
–
Check that the lighting is functioning properly.
–
Position the cover.
400422-12
Info
Check for correct positioning and freedom of movement of the brake lines.
–
Mount and tighten screws .
Guideline
Remaining chassis screws
700335-11
M6
10 Nm (7.4 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
184
Checking the headlight setting
9.62
A
0
–
Stand the vehicle upright on a horizontal surface in front of a light wall and make a
mark at the height of the center of the low beam headlight.
–
Make another mark at a distance  under the first mark.
Guideline
B
0
Distance 
–
5 cm (2 in)
Position the vehicle vertically at a distance  in front of the wall and switch on the low
beam.
Guideline
400420-10
Distance 
5 m (16 ft)
–
The rider, with luggage and passenger if applicable, now mounts the motorcycle.
–
Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark when the motorcycle is
ready to operate with the rider mounted along with any luggage and a passenger if
applicable.
»
If the boundary between light and dark does not meet specifications:
–
Adjust the headlamp range. (
p. 184)
Adjusting the headlamp range
9.63
–
Check the headlight setting. (
p. 184)
MAINTENANCE WORK ON FRAME AND ENGINE
–
185
Turn the screw  to adjust the headlight range.
Guideline
A motorcycle with rider, including the luggage and a passenger (where applicable)
the light cut off must be aligned exactly on the lower mark (when checking headlight
adjustment).
Info
Turn clockwise to increase the light range, turn counterclockwise to reduce the
light range.
If you have a payload, you may have to correct the headlight range.
700285-01
Activating/deactivating ignition key
9.64
Info
The orange programming key must only be used for activating and deactivating!
Loss of a black ignition key (second black ignition key available):
If a black ignition key is lost or replaced, the black ignition keys must be individually
activated/deactivated using the orange programming key. This will also prevent the vehicle from being operated without authorization with the lost black ignition key.
The following procedure deactivates all activated black ignition keys that are not
included in the procedure.
700234-10
–
Press the emergency OFF switch into the position
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up.
.
MAINTENANCE WORK ON FRAME AND ENGINE
186
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
–
Insert the black ignition key in the ignition lock.
–
Switch on the ignition by turning the black programming key to the position ON
EFI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
on again.
lights up, switches off briefly, and switches
–
Switch off the ignition by turning the black programming key to the position OFF
–
Remove the black ignition key.
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
.
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up, switches off briefly, and flashes
according to the number of functioning black ignition keys including the orange
programming key. In this case, twice.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
Loss of both black ignition keys (no black ignition key available):
This procedure is important to prevent misuse of the lost black ignition key.
–
Press the emergency OFF switch into the position
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
.
MAINTENANCE WORK ON FRAME AND ENGINE
The immobilizer indicator lamp
187
lights up.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up, switches off briefly, and flashes
according to the number of functioning black ignition keys including the orange
programming key. In this case once, since all black ignition keys are deactivated.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
All black ignition keys are deactivated.
–
Order a new black ignition key according to the key number on the KEYCODECARD
and activate it.
Activating ignition key:
You can activate or deactivate up to four black ignition keys. Only the black ignition
keys programmed during an activation procedure are valid. All black ignition keys not
programmed during the activation procedure are invalid, but can be reprogrammed in a
further activation procedure.
–
Press the emergency OFF switch into the position
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
–
Insert the black ignition key in the ignition lock.
.
MAINTENANCE WORK ON FRAME AND ENGINE
–
188
Switch on the ignition by turning the black programming key to the position ON
EFI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
on again.
lights up, switches off briefly, and switches
–
Switch off the ignition by turning the black programming key to the position OFF
–
Remove the black ignition key.
–
To activate further ignition keys, repeat the last 4 steps with the respective ignition
key.
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
EFI warning lamp
.
.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
lights up, switches off briefly, and flashes
according to the number of functioning black ignition keys including the orange
programming key.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
All black ignition keys are activated included in this job sequence are activated.
MAINTENANCE WORK ON FRAME AND ENGINE
189
Cooling system
9.65
The water pump with a 3D water pump wheel  in the engine ensures forced circulation of
the coolant. The heat exchanger enables faster warming of the engine oil at the start of a
journey and better heat dissipation for the engine oil during the journey.
The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap . The heat expansion causes the surplus coolant to flow into the compensating
tank . When the temperature falls, this surplus coolant is sucked back into the cooling
system.
400415-10
Cooling takes place by means of the air stream and a radiator fan , which is controlled by
a thermoswitch.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling
effect.
400416-10
Checking the coolant level
9.66
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
MAINTENANCE WORK ON FRAME AND ENGINE
190
Condition
The engine is cold.
The radiator is completely full.
–
Rest the motorcycle on its side stand on a horizontal surface.
–
Check the coolant level in the compensating tank.
The coolant level must be between MIN and MAX.
»
If there is no coolant in the compensating tank:
–
Check the cooling system for leaks.
x
Info
Do not operate the motorcycle!
700324-10
–
»
Add coolant/bleed the cooling system.
x
If the coolant level in the compensating tank does not meet specifications, but the
tank is not empty:
–
Check the cooling system for leaks.
–
Fill the cooling system compensating tank. (
x
p. 190)
Filling the cooling system compensating tank
9.67
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
MAINTENANCE WORK ON FRAME AND ENGINE
191
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact
a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Note
Engine damage Impaired cooling efficiency due to air trapped in 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.)
–
Check the coolant level. (
–
Remove the cap  of the compensating tank.
–
Top up with coolant until the specified coolant level is reached.
p. 189)
Guideline
The coolant level must be between MIN and MAX.
Alternative 1
Coolant (
p. 243)
Alternative 2
700324-01
Coolant (mixed ready to use) (
–
p. 243)
Mount the cap of the compensating tank.
MAINTENANCE WORK ON FRAME AND ENGINE
192
Adjusting basic position of clutch lever
9.68
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
Info
Turn the adjusting screw clockwise to increase the distance between the clutch
lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the
clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
700227-10
Checking fluid level of hydraulic clutch
9.69
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.
MAINTENANCE WORK ON FRAME AND ENGINE
–
193
Check the fluid level.
The fluid level must be between the MIN and MAX markings.
»
If the coolant level does not meet specifications:
–
Correct the fluid level of the hydraulic clutch. (
p. 193)
700350-01
Correcting fluid level of hydraulic clutch
9.70
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
–
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screw cap with membrane.
–
Correct the fuel level.
Guideline
The fluid level must be between the MIN and MAX markings.
Hydraulic fluid (15) (
–
700284-01
p. 245)
Refit the screw cap with the membrane.
MAINTENANCE WORK ON FRAME AND ENGINE
194
Checking the play in the throttle cable
9.71
–
Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the throttle cable.
Throttle cable play
»
3… 5 mm (0.12… 0.2 in)
If the throttle cable play does not meet specifications:
–
Adjust the play in the throttle cable.
x(
p. 195)
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result
in unconsciousness and/or death.
400192-10
–
–
When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
»
If the idle speed changes:
–
Adjust the play in the throttle cable.
x(
p. 195)
MAINTENANCE WORK ON FRAME AND ENGINE
Adjusting the play in the throttle cable
9.72
195
x
–
Move the handlebar to the straight-ahead position.
–
Throttle position sensor circuit A - check in zero position.
x
Info
It is imperative to use the KTM diagnostics tool for this.
700317-01
–
Push back protective cover .
–
Loosen counter nut .
–
Set the play in the throttle cable by turning adjusting screw .
Guideline
Throttle cable play
–
Tighten counter nut .
–
Mount the protective cover.
3… 5 mm (0.12… 0.2 in)
Handlebar height
9.73
By removing or inserting spacing sleeves , you can set the handlebar height at two different positions.
Length of distance sleeve 
15 mm (0.59 in)
With distance sleeves, the handlebar stub is positioned low for sports use. Removing the
distance sleeves gives a more upright sitting position.
Standard
700319-12
Low position with distance sleeve
MAINTENANCE WORK ON FRAME AND ENGINE
196
Adjusting the handlebar height
9.74
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 lacquer when
moving the handlebar stub.
–
Remove screw .
–
Remove distance sleeve .
–
All cables routed under the upper triple clamp must now be routed under the handlebar stub.
–
Push the handlebar stub carefully up to the upper triple clamp.
–
Position the distance sleeve above the triple clamp.
–
Mount and tighten screw.
700318-01
Guideline
Remaining frame bolts
700319-01
M5
5 Nm (3.7 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
–
197
Tighten the screw.
Guideline
Screw, handlebar stub
M8
–
Repeat the adjustments on the other handlebar stub.
–
Move the handlebar to and fro over the entire steering range.
»
If the cables restrict the freedom of movement of the steering:
–
700320-01
20 Nm
(14.8 lbf ft)
Correct the cable routing.
Adjusting the low position of the handlebar stubs:
– Loosen screw .
Info
Loosen the screw several turns to prevent damage to the fork lacquer when
moving the handlebar stub.
700320-11
–
Remove screw  with distance sleeve .
–
Carefully shift the handlebar stub by the length of the distance sleeve.
Guideline
Long distance sleeve
700319-11
15 mm (0.59 in)
–
Lay all cables between the upper triple clamp and the handlebar stub.
–
Position the distance sleeve.
–
Mount and tighten screw.
MAINTENANCE WORK ON FRAME AND ENGINE
198
Guideline
Remaining frame bolts
–
M5
5 Nm (3.7 lbf ft)
M8
20 Nm
(14.8 lbf ft)
Tighten the screw.
Guideline
Screw, handlebar stub
–
Repeat the adjustments on the other handlebar stub.
–
Move the handlebar to and fro over the entire steering range.
»
700362-01
If the cables restrict the freedom of movement of the steering:
–
Correct the cable routing.
Rear frame position
9.75
The frame rear height can be set to two different positions, enabling ergonomic adjustment
of the seat height.
400439-10
Seat height  (standard)
805 mm (31.69 in)
Seat height 
825 mm (32.48 in)
MAINTENANCE WORK ON FRAME AND ENGINE
Adjusting the rear frame position
9.76
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.
–
Remove the seat. (
–
Remove screws  with the bushings.
p. 163)
700363-01
Setting a higher seat position:
– Remove screw  with washer on the left and right sides of the vehicle.
–
700327-10
Push the rear end down until the drill holes of the frame are level with the lower
front drill holes of the rear.
199
MAINTENANCE WORK ON FRAME AND ENGINE
200
–
Mount the screw and washer on the left and right sides of the vehicle, but do not
tighten.
–
Remove screw  with washer on the left and right sides of the vehicle.
–
Push the rear end up until the drill holes of the frame are level with the lower rear
drill holes of the rear.
–
Mount the screw and washer on the left and right sides of the vehicle, and tighten.
700329-01
Guideline
Screw, subframe
M8
20 Nm
(14.8 lbf ft)
Loctite® 243™
700327-11
–
Tighten screw  on the left and right sides of the vehicle.
Guideline
Screw, subframe
700330-01
M8
20 Nm
(14.8 lbf ft)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
201
Setting a lower seat position:
– Remove screw  with washer on the left and right sides of the vehicle.
–
Push the rear end down until the drill holes of the frame are level with the upper
rear drill holes of the rear.
–
Mount the screw and washer on the left and right sides of the vehicle, but do not
tighten.
–
Remove screw  with washer on the left and right sides of the vehicle.
–
Push the rear end up until the drill holes of the frame are level with the upper front
drill holes of the rear.
–
Mount the screw and washer on the left and right sides of the vehicle, and tighten.
700327-12
700327-14
Guideline
Screw, subframe
700329-01
M8
20 Nm
(14.8 lbf ft)
Loctite® 243™
MAINTENANCE WORK ON FRAME AND ENGINE
–
202
Tighten screw  on the left and right sides of the vehicle.
Guideline
Screw, subframe
M8
20 Nm
(14.8 lbf ft)
Loctite® 243™
700327-13
–
When you screw in the rear left fixing screw, the plug-in cable binder  is pushed out
of the thread. To reposition the cable of the lambda sensor, fix the plug-in cable binder
in the remaining free drill hole.
Info
Check the cable routing. The cable of the lambda sensor should not be taut.
700338-01
MAINTENANCE WORK ON FRAME AND ENGINE
–
Position bushings .
–
Mount and tighten screws .
203
Guideline
Remaining chassis screws
–
Fit the seat. (
M6
10 Nm (7.4 lbf ft)
p. 163)
700364-01
Checking the engine oil level
9.77
Info
The engine oil level must be checked at normal engine operating temperature.
–
Stand the motorcycle upright on a horizontal surface.
–
Remove oil dipstick . Check the engine oil level in the measurement range.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil level must be in the middle  of the measurement range of the oil
dipstick.
»
700301-10
If the engine oil level is not at the specified level:
–
–
Add engine oil. (
Replace the oil dipstick.
p. 211)
MAINTENANCE WORK ON FRAME AND ENGINE
Changing engine oil and filter, cleaning oil screen
9.78
204
x
–
Drain the engine oil and clean the oil screens.
–
Fill up with engine oil.
x(
x(
p. 204)
p. 209)
500281-01
Draining engine oil, cleaning oil screens
9.79
x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
–
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
MAINTENANCE WORK ON FRAME AND ENGINE
–
Remove screws .
–
Take off the left exhaust cover .
–
Stand the motorcycle on its side stand on a horizontal surface.
–
Place a suitable container under the engine.
–
Remove oil drain plug  with the magnet, O-rings and oil screen.
–
Remove the oil filter.
–
Completely drain the engine oil.
700302-10
700287-01
x(
p. 207)
205
MAINTENANCE WORK ON FRAME AND ENGINE
206
–
Thoroughly clean the magnet  and oil screen  of the oil drain plug.
–
Mount and tighten the oil drain plugs with the magnet, O-rings and oil screen.
100773-10
Guideline
Oil drain plug
–
700288-01
Install the oil filter.
M20x1.5
x(
p. 209)
20 Nm
(14.8 lbf ft)
MAINTENANCE WORK ON FRAME AND ENGINE
–
Position the left exhaust cover .
–
Mount and tighten screws .
207
Guideline
Screw, trim, painted
M5
3.5 Nm
(2.58 lbf ft)
700302-10
Removing the oil filter
9.80
x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
–
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
MAINTENANCE WORK ON FRAME AND ENGINE
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
–
Place a suitable container under the engine.
–
Remove screws . Take off oil filter cover  with the O-ring.
–
Pull oil filter  out of the oil filter housing.
700289-01
Circlip pliers reverse (51012011000)
700290-01
–
Completely drain the engine oil.
–
Clean the parts and the sealing area thoroughly.
208
MAINTENANCE WORK ON FRAME AND ENGINE
Installing the oil filter
9.81
209
x
–
Insert oil filter .
–
Lubricate the O-ring of the oil filter cover. Mount oil filter cover .
–
Mount and tighten the screws.
Guideline
Remaining engine screws
M5
6 Nm (4.4 lbf ft)
External
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 244)
External
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 244)
700291-01
Filling up with engine oil
9.82
x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
–
The oil must be topped up in two steps.
Engine oil
–
700301-01
3.60 l (3.8 qt.)
Remove the dipstick  and top up the engine oil.
Engine oil (1st
quantity)
3.00 l (3.17 qt.)
External
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 244)
MAINTENANCE WORK ON FRAME AND ENGINE
Engine oil (1st
quantity)
–
3.00 l (3.17 qt.)
210
External
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 244)
Replace the oil dipstick .
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 ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
–
Start the engine and check that it is oil-tight.
–
Remove the dipstick  and pour in the remaining engine oil.
Engine oil (2nd
quantity)
–
0.60 l (0.63 qt.)
External
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 244)
External
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 244)
Replace the oil dipstick .
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 ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
MAINTENANCE WORK ON FRAME AND ENGINE
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
211
p. 203)
Adding engine oil
9.83
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
–
Check the engine oil level. (
–
Remove the dipstick  and add engine oil.
p. 203)
Condition
External temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) (
p. 244)
Condition
External temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) (
700301-01
p. 244)
Info
For optimal performance of the engine oil, do not mix different types of engine
oil.
If appropriate, change the engine oil.
–
Replace oil dipstick .
MAINTENANCE WORK ON FRAME AND ENGINE
212
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 ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
–
Start the engine and check that it is oil-tight.
–
Check the engine oil level. (
p. 203)
TROUBLESHOOTING
213
Faults
Possible cause
Action
Engine doesn't crank when the electric
starter button is pressed
Operating error
–
Carry out the start procedure. (
Battery discharged
–
Recharge the battery.
–
Check closed-circuit current.
Fuse 1 or 6 blown
–
Change the fuses of individual power consumers.
( p. 173)
Main fuse blown
–
Change the main fuse. (
Ignition/steering lock or emergency
OFF switch defective
–
Check the ignition/steering lock.
Safety start system defective
–
Immobilizer active
–
EFI control unit not activated
–
Malfunction in CAN bus communication
–
Combination instrument defective
–
x
Check the emergency OFF switch. x
Read out the trouble code memory using the
KTM diagnostics tool. x
Read the immobilizer blink code.
Encode the EFI control unit. x
Read out the trouble code memory using the
KTM diagnostics tool. x
Check the combination instrument. x
A gear is engaged
–
Shift into neutral.
Safety start system defective
–
Read out the trouble code memory using the
KTM diagnostics tool.
Engine cranks only if the clutch lever
is pulled
–
x(
p. 98)
p. 169)
x
p. 171)
x
Read out the trouble code memory using the
KTM diagnostics tool. x
Engine cranks although it is in gear
Safety start system defective
–
Engine cranks but doesn't start
Fuse 5 blown
–
Change the fuses of individual power consumers.
( p. 173)
Coupling of fuel hose connection not
joined together
–
Join coupling of fuel hose connection together.
TROUBLESHOOTING
214
Faults
Possible cause
Action
Engine cranks but doesn't start
Plug connector of wiring harness oxidized
–
Clean plug connector and treat with contact
spray.
Fault in fuel injection system
–
Read out the trouble code memory using the
KTM diagnostics tool.
Fuel pump control defective
–
Fuel quality insufficient
–
Air filter very dirty
–
Fuel filter very dirty
–
Fault in fuel injection system
–
Too little coolant in cooling system
–
x
Read out the trouble code memory using the
KTM diagnostics tool. x
Add suitable fuel.
Change the air filter. x
Change the fuel filter. x
Read out the trouble code memory using the
KTM diagnostics tool. x
Check the cooling system for leaks. x
–
Check the coolant level. (
Cooling fins very dirty
–
Clean cooling fins.
Kinked or damaged radiator hose
–
Change the coolant hose.
Thermostat defective
–
Check the thermostat.
Fuse 4 blown
–
Change the fuses of individual power consumers.
( p. 173)
Defect in radiator fan system
–
Check the radiator fan system.
Air in cooling system
–
Add coolant/bleed the cooling system.
EFI warning lamp (MIL) lights up /
flashes
Fault in fuel injection system
–
Read out the trouble code memory using the
KTM diagnostics tool.
Engine dies during the journey
Lack of fuel
–
Fill up with fuel. (
Fuse 1, 5 or 6 blown
–
Change the fuses of individual power consumers.
( p. 173)
Engine has too little power
Engine overheats HIGH TEMP
p. 189)
x
x
x
x
x
p. 105)
TROUBLESHOOTING
215
Faults
Possible cause
Action
High oil consumption
Engine oil level too high
–
Check the engine oil level. (
Engine oil too thin (viscosity)
–
Change the engine oil and filter, clean the oil
screen.
( p. 204)
p. 203)
x
Headlight and parking light do not
work
Fuse 2 blown
–
Change the fuses of individual power consumers.
( p. 173)
Brake light and horn do not work
Fuse 3 blown
–
Change the fuses of individual power consumers.
( p. 173)
Battery discharged
Ignition not switched off when vehicle
parked
–
Recharge the battery.
x(
Check charging voltage. x
p. 169)
Battery is not charged by the alternator
–
Combination instrument shows nothing
in display
Fuse 1 blown
–
Change the fuses of individual power consumers.
( p. 173)
Speedometer in combination instrument doesn't work
Wiring harness of wheel revolution
counter damaged or plug-in connector oxidized
–
Check the wheel speed sensor.
x
IMMOBILIZER BLINK CODE
Blink code of immobilizer indicator lamp
12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short
Error level condition
All ignition keys inactive
Blink code of immobilizer indicator lamp
13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short
Error level condition
ICU antenna malfunction
Blink code of immobilizer indicator lamp
14 Immobilizer indicator lamp flashes 1x short, 1 second pause, 4x short
Error level condition
Malfunction in transponder of black ignition key
Blink code of immobilizer indicator lamp
15 Immobilizer indicator lamp flashes 1x short, 1 second pause, 5x short
Error level condition
Black ignition key inactive
Blink code of immobilizer indicator lamp
16 Immobilizer indicator lamp flashes 1x short, 1 second pause, 6x short
Error level condition
Malfunction, encryption, immobilizer control unit to black ignition key
216
IMMOBILIZER BLINK CODE
Blink code of immobilizer indicator lamp
21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short
Error level condition
Immobilizer control unit not activated
Blink code of immobilizer indicator lamp
31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short
Error level condition
Malfunction, encryption query from EFI control unit to immobilizer control unit
Blink code of immobilizer indicator lamp
32 Immobilizer indicator lamp flashes 3x short, 1 second pause, 2x short
Error level condition
Malfunction in CAN bus communication
Blink code of immobilizer indicator lamp
60 Immobilizer indicator lamp flashes 6x short
Error level condition
E²PROM malfunction
217
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
02 EFI warning lamp (MIL) flashes 2x short
Error level condition
Ignition pulse generator - circuit fault
Blink code EFI warning lamp (MIL)
06 EFI warning lamp (MIL) flashes 6x short
Error level condition
Throttle position sensor circuit A - input signal too low
Throttle position sensor circuit A - input signal too high
Blink code EFI warning lamp (MIL)
07 EFI warning lamp (MIL) flashes 7x short
Error level condition
Throttle position sensor circuit B - input signal too low
Throttle position sensor circuit B - input signal too high
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)
11 EFI warning lamp (MIL) flashes 1x long, 1x short
Error level condition
Manifold absolute pressure sensor cylinder 2 - input signal too low
Manifold absolute pressure sensor cylinder 2 - input signal too high
218
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
12 EFI warning lamp (MIL) flashes 1x long, 2x short
Error level condition
Engine coolant temperature sensor - input signal too low
Engine coolant temperature sensor - input signal too high
Blink code EFI warning lamp (MIL)
13 EFI warning lamp (MIL) flashes 1x long, 3x short
Error level condition
Intake air temperature sensor - input signal too low
Intake air temperature sensor - input signal too high
Blink code EFI warning lamp (MIL)
14 EFI warning lamp (MIL) flashes 1x long, 4x short
Error level condition
Ambient air pressure sensor - input signal too low
Ambient air pressure sensor - input signal too high
Blink code EFI warning lamp (MIL)
15 EFI warning lamp (MIL) flashes 1x long, 5x short
Error level condition
Rollover sensor - input signal too low
Rollover sensor - input signal too high
Blink code EFI warning lamp (MIL)
17 EFI warning lamp (MIL) flashes 1x long, 7x short
Error level condition
Lambda sensor cylinder 1, sensor 1 - circuit fault
219
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
18 EFI warning lamp (MIL) flashes 1x long, 8x short
Error level condition
Lambda sensor cylinder 2, sensor 1 - circuit fault
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)
25 EFI warning lamp (MIL) flashes 2x long, 5x short
Error level condition
Side stand switch - circuit fault
Blink code EFI warning lamp (MIL)
33 EFI warning lamp (MIL) flashes 3x long, 3x short
Error level condition
Injector cylinder 1 - circuit fault
Blink code EFI warning lamp (MIL)
34 EFI warning lamp (MIL) flashes 3x long, 4x short
Error level condition
Injector cylinder 2 - circuit fault
220
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
37 EFI warning lamp (MIL) flashes 3x long, 7x short
Error level condition
Ignition coil cylinder 1 - circuit fault
Blink code EFI warning lamp (MIL)
38 EFI warning lamp (MIL) flashes 3x long, 8x short
Error level condition
Ignition coil cylinder 2 - circuit fault
Blink code EFI warning lamp (MIL)
41 EFI warning lamp (MIL) flashes 4x long, 1x short
Error level condition
Fuel pump controller - short circuit to ground or open circuit
Fuel pump controller - input signal too high
Blink code EFI warning lamp (MIL)
45 EFI warning lamp (MIL) flashes 4x long, 5x short
Error level condition
Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit
Lambda sensor heater cylinder 1, sensor 1 - input signal too high
Blink code EFI warning lamp (MIL)
46 EFI warning lamp (MIL) flashes 4x long, 6x short
Error level condition
Lambda sensor heater cylinder 2, sensor 1 - short circuit to ground or open circuit
Lambda sensor heater cylinder 2, sensor 1 - input signal too high
221
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
49 EFI warning lamp (MIL) flashes 4x long, 9x short
Error level condition
Motor drive circuit A - circuit fault
Blink code EFI warning lamp (MIL)
50 EFI warning lamp (MIL) flashes 5x long
Error level condition
Throttle position sensor actuator circuit B - circuit fault
Blink code EFI warning lamp (MIL)
53 EFI warning lamp (MIL) flashes 5x long, 3x short
Error level condition
Fuel evaporation valve - short circuit to ground or open circuit
Fuel evaporation valve - input signal too high
Blink code EFI warning lamp (MIL)
54 EFI warning lamp (MIL) flashes 5x long, 4x short
Error level condition
Secondary air valve - short circuit to ground or open circuit
Secondary air valve - input signal too high
Blink code EFI warning lamp (MIL)
68 EFI warning lamp (MIL) flashes 6x long, 8x short
Error level condition
Manifold absolute pressure sensor cylinder 1 - connection leaks
222
ENGINE CONTROL BLINK CODE
Blink code EFI warning lamp (MIL)
69 EFI warning lamp (MIL) flashes 6x long, 9x short
Error level condition
Manifold absolute pressure sensor cylinder 2 - connection leaks
Blink code EFI warning lamp (MIL)
81 EFI warning lamp (MIL) flashes 8x long, 1x short
Error level condition
Immobilizer control unit - circuit fault
Blink code EFI warning lamp (MIL)
91 EFI warning lamp (MIL) flashes 9x long, 1x short
Error level condition
CAN bus communication error
223
CLEANING
224
Cleaning motorcycle
13.1
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 electrical
components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
–
Before cleaning, seal the exhaust system to prevent water from entering.
–
Remove loose dirt first with a soft jet of water.
–
Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.
Motorcycle cleaner (
p. 248)
Info
Use warm water mixed with a normal commercial engine cleaner and a soft sponge.
If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.
–
After cleaning the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
CLEANING
225
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–
–
Clean or dry dirty or wet brakes by riding and braking gently.
After cleaning, ride a short distance until operating temperature is reached, and apply the brakes.
Info
The heat causes water to evaporate from inaccessible parts of the engine and brakes.
–
After the engine has cooled down, lubricate or grease all moving parts and bearings.
–
Clean the chain. (
–
Treat bare metal (except for brake discs and the exhaust system) with an anticorrosive.
p. 136)
Cleaning and preserving materials for metal, rubber and plastic (
–
p. 247)
Treat all painted parts with a mild lacquer care spray.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces (
–
Oil the ignition/steering lock, tank lock, and seat lock.
Universal oil spray (
p. 248)
p. 248)
PROTECTIVE TREATMENT FOR WINTER OPERATION
Conservation for winter operation
14.1
Info
If you use the motorcycle in the winter, you have to expect salt on the roads. You therefore have to take precautions against the
aggressive road salt.
If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.
–
Clean the motorcycle. (
–
Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.
p. 224)
Info
Avoid getting anticorrosive on the brake discs: this would badly affect the braking.
After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.
–
Clean the chain. (
p. 136)
226
STORAGE
227
Storage
15.1
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the
new season.
–
Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
–
Clean the motorcycle. (
–
Change the engine oil and filter, clean the oil screen.
–
Check the coolant level. (
–
Check the antifreeze.
–
–
–
p. 224)
x
Check the tire pressure. (
Remove the battery. x (
Recharge the battery. x (
x(
p. 204)
p. 189)
p. 162)
p. 165)
p. 169)
Guideline
Storage temperature of battery without direct sunshine.
–
0… 35 °C (32… 95 °F)
The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.
–
Jack up the motorcycle at the rear. (
–
Jack up the motorcycle at the front. (
–
Cover the motorcycle with a porous sheet or blanket.
p. 111)
p. 110)
STORAGE
228
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage
15.2
–
Take the front of the motorcycle off the work stand. (
–
Take the rear from the work stand. (
–
Recharge the battery.
–
Install the battery.
–
Set the clock with SET CLOCK. (
–
Fill up with fuel. (
–
Make checks before putting into operation. (
–
Take a test ride.
p. 111)
x ( p. 169)
x ( p. 167)
p. 78)
p. 105)
p. 97)
p. 110)
TECHNICAL DATA - ENGINE
229
Design
2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled
Displacement
1,150 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 cylinder, chain-driven
Valve - valve stem diameter
Intake
42 mm (1.65 in)
Exhaust
34 mm (1.34 in)
Valve clearance
Exhaust at: 20 °C (68 °F)
0.25… 0.30 mm (0.0098… 0.0118 in)
Intake at: 20 °C (68 °F)
0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing
Sleeve bearing
Conrod bearing
Sleeve bearing
Piston pin bearing
No bearing bushes - DLC-coated piston pins
Piston
Forged light alloy
Piston ring
1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication
Dry sump lubrication system with three rotor pumps
Primary transmission
40:76
Clutch
Multi-disc clutch in oilbath / hydraulically operated
Transmission
6-speed claw gears
Transmission ratio
1st gear
14:36
2nd gear
16:30
3rd gear
20:30
TECHNICAL DATA - ENGINE
230
4th gear
21:27
5th gear
23:26
6th gear
25:26
Mixture preparation
Electronically controlled fuel injection
Ignition system
Contactless controlled fully electronic ignition with digital ignition
adjustment
Alternator
12 V, 390 W
Spark plug
NGK LKAR9BI9
Electrode gap, spark plug
0.8… 0.9 mm (0.031… 0.035 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Idle speed
1,500… 1,600 rpm
Cold start device
Electric starter
Capacity - engine oil
16.1
Engine oil
3.60 l (3.8 qt.)
External temperature: ≥ 0 °C
(≥ 32 °F)
Engine oil (SAE 10W/50)
( p. 244)
External temperature: < 0 °C
(< 32 °F)
Engine oil (SAE 5W/40)
( p. 244)
Capacity - coolant
16.2
Coolant
2.60 l (2.75 qt.)
Coolant (
p. 243)
Coolant (mixed ready to use) (
p. 243)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
231
Hose clip, intake flange
M4
1.5 Nm (1.11 lbf ft)
–
Remaining engine screws
M5
6 Nm (4.4 lbf ft)
–
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, gear sensor
M5
3 Nm (2.2 lbf ft)
Loctite® 243™
Screw, pulse generator
M5
10 Nm (7.4 lbf ft)
Loctite® 243™
Freewheel ring bolt
M6 – 10.9
15 Nm (11.1 lbf ft)
Loctite® 648™
Nut, cylinder head
M6
9 Nm (6.6 lbf ft)
–
Plug, vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite® 243™
Remaining engine screws
M6
10 Nm (7.4 lbf ft)
–
Screw, camshaft bearing support
M6 – 10.9
10 Nm (7.4 lbf ft)
–
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch spring
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, coolant connection on cylinder
head
M6
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x60
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x80
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x90
10 Nm (7.4 lbf ft)
–
Screw, freewheel holder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, locking lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, oil pump cover
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, starter motor
M6
10 Nm (7.4 lbf ft)
–
Screw, stator clamp
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
232
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
–
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
–
Screw, water pump wheel
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Stud, chain shaft
M6
8 Nm (5.9 lbf ft)
–
Vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite® 243™
Oil jet
M6x0.75
4 Nm (3 lbf ft)
Loctite® 243™
Plug, crankshaft retainer
M8
15 Nm (11.1 lbf ft)
–
Screw, camshaft bearing support
M8 – 10.9
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
–
Screw, camshaft bearing support
M8 – 10.9
Step 1
8.5 Nm (6.27 lbf ft)
Step 2
14.5 Nm (10.7 lbf ft)
Only applies when using:
Hex key bit (61229025000)
Screw, engine case
M8
18 Nm (13.3 lbf ft)
–
Screw, engine console
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, heat exchanger
M8
15 Nm (11.1 lbf ft)
–
Screw, timing chain guide rail
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, timing chain tensioning rail
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Stud, exhaust flange
M8
10 Nm (7.4 lbf ft)
–
Oil pressure sensor
M10x1
10 Nm (7.4 lbf ft)
–
Plug, cam lever axis
M10x1
15 Nm (11.1 lbf ft)
–
Plug, clutch lubrication
M10x1
15 Nm (11.1 lbf ft)
–
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
233
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:
Using a crisscross pattern
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Step 4
90°
Lubricated with engine oil
Coolant temperature sensor
M12x1.5
12 Nm (8.9 lbf ft)
–
Rotor screw
M12x1.5
90 Nm (66.4 lbf ft)
–
Spark plug
M12x1.5
17 Nm (12.5 lbf ft)
–
Nut of engine sprocket
M20x1.5
100 Nm (73.8 lbf ft)
Loctite® 243™
Oil drain plug
M20x1.5
20 Nm (14.8 lbf ft)
–
Nut, inner clutch hub
M22x1.5
130 Nm (95.9 lbf ft)
Loctite® 243™
Plug, timing-chain tensioner
M24x1.5
25 Nm (18.4 lbf ft)
–
Screw in alternator cover
M24x1.5
8 Nm (5.9 lbf ft)
–
Nut, primary gear
M33LHx1.5
130 Nm (95.9 lbf ft)
Loctite® 243™
TECHNICAL DATA - CHASSIS
234
Frame
Lattice frame made of chromium molybdenum steel tubing,
powder-coated
Fork
WP Suspension Up Side Down 4354
Shock absorber
WP Suspension 4014 VP
Suspension travel
Front
120 mm (4.72 in)
Rear
125 mm (4.92 in)
Brake system
Front
Twin floating disc with radial mount, 4-piston calipers
Rear
Single non-floating disc with 2 piston brake caliper
Brake discs - diameter
Front
320 mm (12.6 in)
Rear
220 mm (8.66 in)
Brake discs - wear limit
Front
4.0 mm (0.157 in)
Brake disc - wear limit
Rear
4.5 mm (0.177 in)
Tire air pressure, solo
Front
2.5 bar (36 psi)
Rear
2.5 bar (36 psi)
Tire air pressure with passenger / full payload
Front
2.5 bar (36 psi)
Rear
2.9 bar (42 psi)
Secondary drive
17:38
Chain
5/8 x 5/16” X‑ring
TECHNICAL DATA - CHASSIS
235
Steering head angle
66.7°
Wheelbase
1,430 mm (56.3 in)
Seat height, unloaded
Lower frame rear position
805 mm (31.69 in)
Upper frame rear position
825 mm (32.48 in)
Ground clearance, unloaded
110 mm (4.33 in)
Weight without fuel approx.
184 kg (406 lb.)
Maximum permissible front axle load
150 kg (331 lb.)
Maximum permissible rear axle load
240 kg (529 lb.)
Maximum permissible total weight
380 kg (838 lb.)
Battery
YTZ14S
Battery voltage: 12 V
Nominal capacity: 11.2 Ah
maintenance-free
Fuse
58011109130
30 A
Fuse
75011088015
15 A
Fuse
75011088010
10 A
Low beam / high beam
H7 / base PX26d
12 V
55 W
Parking light
W5W / base W2.1x9.5d
12 V
5W
Instrument lights and control lamps
LED
Turn signal
LED
Brake/tail light
LED
Lighting equipment
18.1
TECHNICAL DATA - CHASSIS
License plate lamp
236
W5W / base W2.1x9.5d
12 V
5W
Tires
18.2
Front tire
Rear tire
120/70 ZR 17 M/C 58W TL
Pirelli Diabolo Rosso
190/55 ZR 17 M/C 75W TL
Pirelli Diabolo Rosso
Additional information is available in the Service section under:
http://www.ktm.com
Capacity - fuel
18.3
Total fuel tank capacity, approx.
Fuel reserve, approx.
16.5 l (4.36 US gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
3.5 l (3.7 qt.)
p. 246)
TECHNICAL DATA - FORK
237
Fork part number
05.18.7J.07
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
Comfort
5 turns
Standard
5 turns
Sport
3 turns
Full payload
3 turns
Spring length with preload spacer(s)
405 mm (15.94 in)
Spring rate
Medium (standard)
9.5 N/mm (54.2 lb/in)
Air chamber length
+0.79
80+20
−10 mm (3.15−0.39 in)
Fork length
735 mm (28.94 in)
Fork oil per fork leg
520 ml (17.58 fl. oz.)
Fork oil (SAE 5) (
p. 245)
TECHNICAL DATA - SHOCK ABSORBER
Shock absorber part number
17.18.7E.07
Shock absorber
WP Suspension 4014 VP
Compression damping, high-speed
Comfort
3 turns
Standard
2.5 turns
Sport
1.5 turns
Full payload
1.5 turns
Compression damping, low-speed
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
5 clicks
Full payload
10 clicks
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)
Spring rate
Medium (standard)
Spring length
95 N/mm (542 lb/in)
160 mm (6.3 in)
238
TECHNICAL DATA - SHOCK ABSORBER
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)
Shock absorber oil (
p. 245)
SAE 2,5
239
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
240
Screw, side stand switch
M4
2 Nm (1.5 lbf ft)
Loctite® 243™
Remaining frame bolts
M5
5 Nm (3.7 lbf ft)
–
Screw, brake fluid reservoir of rear brake
M5
5 Nm (3.7 lbf ft)
Loctite® 243™
Screw, brake line holder
M5
5 Nm (3.7 lbf ft)
–
Screw, chain guard
M5
5 Nm (3.7 lbf ft)
–
Screw, chain sliding piece
M5
5 Nm (3.7 lbf ft)
–
Screw, fuel level indicator
M5
3 Nm (2.2 lbf ft)
–
Screw, fuel tank guard
M5x12
3 Nm (2.2 lbf ft)
–
Screw, steering damper fixing bracket
M5
5 Nm (3.7 lbf ft)
Loctite® 243™
Screw, trim, painted
M5
3.5 Nm (2.58 lbf ft)
–
Bolt, foot brake lever stub
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Remaining chassis nuts
M6
15 Nm (11.1 lbf ft)
–
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
–
Screw, exhaust clamp
M6
8 Nm (5.9 lbf ft)
–
Screw, exhaust heat shield
M6
15 Nm (11.1 lbf ft)
–
Screw, foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, foot brake lever
M6
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, fuel pump
M6
6 Nm (4.4 lbf ft)
–
Screw, shift lever stub
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift rod
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, shift shaft deflector on chain
securing guide
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift shaft deflector on shift
shaft
M6
18 Nm (13.3 lbf ft)
Loctite® 243™
Fork end pinch bolts
M8
15 Nm (11.1 lbf ft)
–
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
241
Nut, forked bracket on foot brake lever
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Remaining chassis nuts
M8
30 Nm (22.1 lbf ft)
–
Remaining chassis screws
M8
25 Nm (18.4 lbf ft)
–
Screw of rear brake caliper
M8
22 Nm (16.2 lbf ft)
Loctite® 243™
Screw, bottom triple clamp
M8
15 Nm (11.1 lbf ft)
–
Screw, clamp, eccentric shaft of deflector
M8
18 Nm (13.3 lbf ft)
–
Screw, front brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, front footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, handlebar stub
M8
20 Nm (14.8 lbf ft)
–
Screw, ignition lock
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, rear brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, rear footrest bracket
M8
25 Nm (18.4 lbf ft)
–
Screw, shift lever
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, side stand bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, spring holder on side stand
bracket
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, steering damper clamp on console
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, steering damper fixing bracket
on triple clamp
M8
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
–
Screw, subframe
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, top triple clamp
M8
17 Nm (12.5 lbf ft)
–
Screw, work stand adapter
M8
18 Nm (13.3 lbf ft)
–
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
242
Remaining chassis nuts
M10
50 Nm (36.9 lbf ft)
–
Remaining chassis screws
M10
45 Nm (33.2 lbf ft)
–
Screw, connecting lever, shock absorber
deflector
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, engine bearer
M10
45 Nm (33.2 lbf ft)
–
Screw, shock absorber
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, side stand
M10
35 Nm (25.8 lbf ft)
Loctite® 243™
Rear sprocket bolt
M10x1.25
50 Nm (36.9 lbf ft)
Loctite® 243™
Screw, front brake caliper
M10x1.25
45 Nm (33.2 lbf ft)
Loctite® 243™
Nut of bell crank on frame
M14x1.5
100 Nm (73.8 lbf ft)
–
Lambda sensor
M18x1.5
45 Nm (33.2 lbf ft)
–
Nut, swingarm pivot
M19x1.5
130 Nm (95.9 lbf ft)
Thread greased
Screw, seat lock
M22x1.5
8 Nm (5.9 lbf ft)
–
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)
–
SUBSTANCES
243
Brake fluid DOT 4 / DOT 5.1
According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13…
−49 °F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Coolant (mixed ready to use)
Antifreeze
Supplier
Motorex®
– Anti Freeze
−40 °C (−40 °F)
SUBSTANCES
244
Engine oil (SAE 10W/50)
According to
– JASO T903 MA (
–
SAE (
p. 249)
p. 249) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
Engine oil (SAE 5W/40)
According to
– JASO T903 MA (
–
SAE (
p. 249)
p. 249) (SAE 5W/40)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
SUBSTANCES
245
Fork oil (SAE 5)
According to
– SAE ( p. 249) (SAE 5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Racing Fork Oil
Hydraulic fluid (15)
According to
– ISO VG (15)
Guideline
– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2,5) (50180342S1)
According to
– SAE ( p. 249) (SAE 2,5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties.
SUBSTANCES
Super unleaded (ROZ 95 / RON 95 / PON 91)
According to
– DIN EN 228 (ROZ 95 / RON 95 / PON 91)
246
AUXILIARY SUBSTANCES
Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean 611
Chain lube for road use
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Lube 622 Strong
Cleaning and preserving materials for metal, rubber and plastic
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Protect & Shine 645
Long-life grease
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Fett 2000
247
AUXILIARY SUBSTANCES
Motorcycle cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Clean 900
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Clean & Polish
Universal oil spray
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Joker 440 Universal
248
STANDARDS
249
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for
motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
250
A
Braking
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C
B
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INDEX
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Blank time of the LAP button LAP BLANK T
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Blink code
engine control . . . . . . . . . . . . . . . . . . . . . . . . . . 218-223
immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216-217
Brake disc of rear brake
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Brake discs, front
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Brake fluid
of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 149
topping up for front brake . . . . . . . . . . . . . . . . . . . . . . 146
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 145
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 148
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224-225
Clutch
fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 192
fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . . . 193
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . . 192
Combination instrument
activation and test . . . . . . . .
CHANGE MODE menu . . . . . . .
display . . . . . . . . . . . . . . . .
DISTANCE TO Next Service menu
FUELDISTANCE menu . . . . . . .
FUELRANGE menu . . . . . . . . .
function buttons, handlebar . .
indicator lamps . . . . . . . . . .
info display . . . . . . . . . . . . .
LAP menu, LAP BLANK T button
LAP/BESTLAP/LastLap menu . . .
....
....
....
...
....
....
....
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. . . . . . 36
59, 73, 75
. . . . . . 37
49, 72, 75
47, 72, 75
48, 72, 75
. . . . . . 35
. . . . . . 39
. . . . . . 38
63, 73, 75
53, 72, 75
INDEX
LAP/BESTLAP/TopSpeed menu . . . . . . . . . .
LAPSTOGO menu . . . . . . . . . . . . . . . . . . .
notes/warnings . . . . . . . . . . . . . . . . . . . .
odometer menu ODO/Trip 1 . . . . . . . . . . . .
odometer menu ODO/Trip 2 . . . . . . . . . . . .
OPTIONS menu . . . . . . . . . . . . . . . . . . . .
OUTERTEMP menu . . . . . . . . . . . . . . . . . .
SET °C/°F menu . . . . . . . . . . . . . . . . . . .
SET CLOCK menu . . . . . . . . . . . . . . . . . . .
SET KM/MILES menu . . . . . . . . . . . . . . . .
SET NUM LAPS menu . . . . . . . . . . . . . . . .
SETTINGS menu . . . . . . . . . . . . . . . . . . .
SET‑UP menu . . . . . . . . . . . . . . . . . . . . .
SHIFT RPMS menu . . . . . . . . . . . . . . . . . .
TOPSPEED menu . . . . . . . . . . . . . . . . . . .
total distance menu in Race mode RACEODO
TPMS menu . . . . . . . . . . . . . . . . . . . . . .
TRIP F RESET menu . . . . . . . . . . . . . . . . .
UNITS menu . . . . . . . . . . . . . . . . . . . . . .
251
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54, 73, 75
51, 72, 75
. . . . . . 40
45, 72, 75
46, 72, 75
69, 74, 76
71, 74, 76
68, 74, 76
60, 73, 75
67, 74, 76
64, 74-75
61, 73, 75
58, 73, 75
62, 73, 75
52, 72, 75
55, 73, 75
70, 74, 76
65, 74, 76
66, 74, 76
Conservation for winter operation . . . . . . . . . . . . . . . . . . . . . 226
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
filling compensating tank . . . . . . . . . . . . . . . . . . . . . . . 190
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine oil
adding .
changing
draining
refilling .
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211
204
204
209
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
External temperature display
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
F
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
checking free travel . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Foot brake lever stub
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INDEX
252
Footrest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
attaching to vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
compression damping, adjusting . . . . . . . . . . . . . . . . .
fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . .
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . .
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . .
112
112
115
113
114
High beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ignition key
activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . . . 185
Fork part number
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Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
I
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
K
Fuel reserve display TRIP F RESET
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuse
individual power consumers, changing . . . . . . . . . . . . . . 173
Kilometers/miles SET KM/MILES
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
H
L
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . 145
Lap times
displaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Handlebar
handlebar height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
handlebar height, adjusting . . . . . . . . . . . . . . . . . . . . . 196
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Headlight adjustment
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Luggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INDEX
253
M
P
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Parking
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maximum speed
displaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Motorcycle
cleaning . . . . . . . . . . . . .
jacking up front . . . . . . . .
jacking up rear . . . . . . . . .
taking front off work stand .
taking rear from work stand
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224
110
111
110
111
N
Number of laps SET NUM LAPS
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Play in the throttle cable
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Protective treatment for winter operation . . . . . . . . . . . . . . . . 226
Putting into operation
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
checks to be made before putting into operation . . . . . . . . 97
R
RACE mode
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rear frame position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Rear hub cush drive
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INDEX
254
compression damping, high-speed, adjusting
compression damping, low-speed, adjusting .
rebound damping, adjusting . . . . . . . . . . . .
spring preload, adjusting . . . . . . . . . . . . . .
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ROAD mode
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
S
Seat
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 107-109
SET °C/°F temperature unit
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SET CLOCK
setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Shift lever stub
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Shift speed RPM1/2
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Shock absorber part number
Side stand . . . . . . . . . . . .
Spare parts . . . . . . . . . . .
Starting . . . . . . . . . . . . .
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117
116
118
119
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..8
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Steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Steering damper part number
Steering lock . . . . . . . . . .
Stopping . . . . . . . . . . . . .
Storage . . . . . . . . . . . . .
Supporting strap . . . . . . . .
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. 28
. 32
104
227
. 88
Technical data
chassis . . . . . . . . . . . . .
chassis tightening torques
engine . . . . . . . . . . . . .
engine tightening torques
fork . . . . . . . . . . . . . . .
shock absorber . . . . . . . .
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234-236
240-242
229-230
231-233
. . . . 237
238-239
T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
compression damping, general . . . . . . . . . . . . . . . . . . . 116
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Shifting
INDEX
255
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Transport . . . . .
Troubleshooting .
Turn signal switch
Type label . . . . .
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......9
213-215
. . . . . 31
. . . . . 26
U
Use definition
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V
Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . 26
Vehicle level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
front, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
rear, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
rear right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
*3211524en*
3211524en
12/2009
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer
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