KTM 1190 RC8 R EU/UK 2009 Repair Manual

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[Page 1] KTM 1190 RC8 R EU/UK 2009

REPAIR MANUAL 2009 1190 RC8 R EU/UK 1190 RC8 R AUS 1190 RC8 R FR 1190 RC8 R JP Article no. 3206077en PartShark.com 877-999-5686 ...

[Page 2] KTM 1190 RC8 R EU/UK 2009

PartShark.com 877-999-5686 ...

[Page 3] KTM 1190 RC8 R EU/UK 2009

INTRODUCTION 1 INTRODUCTION Read this repair manual carefully and thoroughly before beginning work. Only use ORGINAL KTM SPARE PARTS. The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly ...

[Page 4] KTM 1190 RC8 R EU/UK 2009

CONTENTS 2 CONTENTS MEANS OF REPRESENTATION ............................................ 6 IMPORTANT NOTES............................................................ 7 LOCATION OF SERIAL NUMBERS ........................................ 8 Vehicle ide...

[Page 5] KTM 1190 RC8 R EU/UK 2009

CONTENTS 3 Fuel pump relay ............................................................ 88 Removing the battery..................................................... 88 Installing the battery...................................................... 89 Re...

[Page 6] KTM 1190 RC8 R EU/UK 2009

CONTENTS 4 Preparing the timing chain tensioner for installation ....... 154 Checking the oil pressure regulator valve........................ 155 Checking the oil pumps................................................ 155 Checking the clutch............

[Page 7] KTM 1190 RC8 R EU/UK 2009

CONTENTS 5 Reinstalling the throttle valve body when the adjustments have been made........................................ 222 Throttle position sensor circuit B................................... 223 Manifold absolute pressure sensor..................

[Page 8] KTM 1190 RC8 R EU/UK 2009

MEANS OF REPRESENTATION 6 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page ref...

[Page 9] KTM 1190 RC8 R EU/UK 2009

IMPORTANT NOTES 7 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 m...

[Page 10] KTM 1190 RC8 R EU/UK 2009

LOCATION OF SERIAL NUMBERS 8 3.1Vehicle identification number/type label 100654-10 The vehicle identification number  is stamped on the frame behind the steering head on the right. The type label  is on the frame above the vehicle identificatio...

[Page 11] KTM 1190 RC8 R EU/UK 2009

LOCATION OF SERIAL NUMBERS 9 3.6Steering damper part number 100658-10 The steering damper part number  is stamped on the top of the steering damper. PartShark.com 877-999-5686 ...

[Page 12] KTM 1190 RC8 R EU/UK 2009

MOTORCYCLE 10 4.1Jacking up motorcycle front Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle at the rear. ( p. 13) 100679-10 – Move the handl...

[Page 13] KTM 1190 RC8 R EU/UK 2009

MOTORCYCLE 11 200600-01 – Screw the holder of the special tool all the way into the lower drill holes of the footrest brackets. Select the required height and width of the work stand. Work stand (62529055000) ( p. 447) – Jack up the motorcycle. I...

[Page 14] KTM 1190 RC8 R EU/UK 2009

MOTORCYCLE 12 200598-11 – Position the footrest bracket. Mount and tighten screws . Guideline Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite ® 243™ – Position the shift rod. Mount and tighten screw . Guideline Screw, shift ...

[Page 15] KTM 1190 RC8 R EU/UK 2009

MOTORCYCLE 13 200597-01 – Remove the motorcycle from the work stand and rest it on the side stand. – Remove the work stand. Work stand (62529055000) ( p. 447) 4.7Jacking up motorcycle at the rear Note Danger of damage The parked vehicle can rol...

[Page 16] KTM 1190 RC8 R EU/UK 2009

MOTORCYCLE 14 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. 100677-10 – Press the emergency OFF switch into the position . – ...

[Page 17] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 15 5.1Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. An optimally adjusted compression damping ensures that the fork does not compress too far and fa...

[Page 18] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 16 5.3Adjusting the spring preload of the fork Info Spring preload determines the initial fork position. The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, a...

[Page 19] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 17 5.5Vehicle level 100693-01 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 ...

[Page 20] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 18 100694-11 – Tighten screw . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Tighten screws . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) – Tighten screw . Guideline Screw, handlebar s...

[Page 21] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 19 201058-10 – Remove screws . Hang the wheel speed sensor to the side. 201059-10 – Unscrew screws  of the triple clamps and handlebar stubs. Remove the fork legs downward. 5.8Installing the fork Warning Danger of acci...

[Page 22] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 20 201057-11 – Position the fender. Mount and tighten screws . Guideline Remaining chassis screws M6 10 Nm (7.4 lbf ft) 100781-11 – Clean and grease the shaft seal rings  and mating surfaces  of the spacers. Long-li...

[Page 23] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 21 100782-11 – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Tighten screws . Guideline Fork end pinch bolts M8 15 Nm (11.1 lbf ft) 5.9performing a fork service Info These ...

[Page 24] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 22 200606-10 – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T612S) ( p. 451) 200607-10 – Release Preload Adjuster . Key (T524) ( p. 450) Info The Preload Adjuster cannot be removed yet. – Un...

[Page 25] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 23 200611-10 – Remove adjusting tube . 200612-10 – Screw special tool  onto the piston rod and pull it up. Gripping tool (T14026S1) ( p. 449) – Remove the special tool from the hexagonal piece. Open-end wrench (T1403...

[Page 26] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 24 200616-10 – Clamp the fork leg with the axle clamp. – Remove screws . 200617-10 – Unscrew screws  of the cartridge and remove with the seal ring. Info Place a drain pan underneath. 200618-10 – Remove the c...

[Page 27] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 25 200620-10 – Remove lock ring . 200621-10 – Remove seal ring . 200622-10 – Remove support ring . 5.12Checking the fork legs Condition The fork legs must be disassembled. 200629-10 – Check the inner tube and ax...

[Page 28] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 26 200631-10 – Measure the run-out of the inner tube. Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in) » If the measured value is greater than the specified value: – Change the inner tube. 200632-10 – Check the outer tub...

[Page 29] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 27 5.14Assembling the outer tubes Info These operations are the same on both outer tubes. – Check the fork legs. ( p. 25) 200622-11 – Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T612S) ( p. 45...

[Page 30] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 28 200618-11 – Slide the cartridge into the inner tube with spring seat  and the preload bush. 200626-10 – Clamp the fork leg with the axle clamp. – Mount and tighten screw . Guideline Screw, cartridge M12x1 25 Nm (1...

[Page 31] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 29 200624-10 – Slide on collar bushing . – Slide adjusting tube  into the piston rod. 200627-10 – Install the special tool. Gripping tool (T14026S1) ( p. 449) Info The special tool must be used to prevent the adjusti...

[Page 32] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 30 200628-10 – Unscrew the special tool from the piston rod. Gripping tool (T14026S1) ( p. 449) – Lubricate the thread of the piston rod. Lubricant (T159) ( p. 438) – Lubricate the upper edge of the piston rod. Lubricant (...

[Page 33] KTM 1190 RC8 R EU/UK 2009

01/FORK, TRIPLE CLAMP 31 Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Compression damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks – Turn the adjusting screw of...

[Page 34] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 32 6.1Adjusting basic position of clutch lever 100751-10 – 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...

[Page 35] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 33 100759-01 – Tighten the screw. Guideline Screw, handlebar stub M8 20 Nm (14.8 lbf ft) – Repeat the adjustments on the other handlebar stub. – Move the handlebar to and fro over the entire steering range...

[Page 36] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 34 6.5Throttle grip 100783-10 The installed throttle grip  twists opens uniformly (linear) over the entire range of the throttle valve. The throttle grip  supplied does not open the throttle valves as wide...

[Page 37] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 35 301449-10 – Turn the handlebar all the way to the right. – Turn the handlebar stub to the left. – Remove the throttle grip. 301450-10 – Push back protective cover . – Unscrew lock nut . – Sc...

[Page 38] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 36 301455-10 Throttle grip with code 5209: – Check that angle piece  of the throttle cable (closer) is seated correctly. Guideline Distance  9… 11 mm (0.35… 0.43 in) » If the specified value is not ...

[Page 39] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 37 301448-10 – Align the handlebar stub. – Position the distance sleeves. – Mount screw  but do not tighten them yet. – Tighten screw . Guideline Screw, handlebar stub M8 20 Nm (14.8 lbf ft) – Ti...

[Page 40] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 38 301459-10 – Unscrew lock nut . – Screw in angle piece  until it is seated correctly. Guideline Distance  9… 11 mm (0.35… 0.43 in) 301458-10 – Route the throttle cable so it is not under ten...

[Page 41] KTM 1190 RC8 R EU/UK 2009

02/HANDLEBAR, CONTROLS AND INSTRUMENTS 39 301460-10 – Ensure that rubber grommets  are seated correctly. – Install the air filter. ( p. 67) – Install the fuel tank. ( p. 71) PartShark.com 877-999-5686 ...

[Page 42] KTM 1190 RC8 R EU/UK 2009

03/FRAME 40 7.1Side stand switch 900040-60 Installation location – The side stand switch is fitted to the side stand. Side stand switch, connector AR ( p. 394) pin assignment Side stand signal "SSTAND SW" Retracted Side stand signal "...

[Page 43] KTM 1190 RC8 R EU/UK 2009

03/FRAME 41 100702-01 – Repeat adjustment work on the footrest bracket on the other side. – Adjust the shift lever. ( p. 192) – Adjust the foot brake pedal. ( p. 100) 7.4Rear frame position 400439-10 The frame rear height can be set to two diff...

[Page 44] KTM 1190 RC8 R EU/UK 2009

03/FRAME 42 100765-10 – 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 th...

[Page 45] KTM 1190 RC8 R EU/UK 2009

03/FRAME 43 100767-10 – 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 ...

[Page 46] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 44 8.1Adjusting the low-speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere ...

[Page 47] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 45 8.3Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the descrip...

[Page 48] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 46 100689-11 – Tighten screw . Guideline Remaining frame bolts M5 5 Nm (3.7 lbf ft) 8.5Adjusting the vehicle level at the rear Warning Danger of accidents Modifications to the suspension settings can seriously alter...

[Page 49] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 47 200603-10 – Remove screw . – Remove upper screw  of the shock absorber. – Remove nut . Pull out the pin of bell crank  on the frame. Remove the bell crank. 200604-01 – Remove the shock absorber towar...

[Page 50] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 48 8.8Servicing the shock absorber Condition The shock absorber has been removed. 201094-01 – Remove the spring. ( p. 48) – Disassemble the damper. ( p. 49) – Disassemble the piston rod. ( p. 50) – Check the damper...

[Page 51] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 49 8.10Disassembling the damper – Remove the spring. ( p. 48) 200563-10 – Determine and note down the current setting of the rebound and compression damping. – Completely open the adjusting elements of the rebound an...

[Page 52] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 50 200569-10 – Remove compression damping adjuster . Remove the spring, sleeve and piston. 8.11Disassembling the piston rod – Disassemble the damper. ( p. 49) 200570-10 – Clamp the piston rod into a vise with the ...

[Page 53] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 51 200573-10 – Remove seal ring retainer . 200574-10 – Remove locking cap  and rubber buffer . 8.12Checking the damper Condition The damper has been disassembled. 300601-10 – Measure the inside diameter at b...

[Page 54] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 52 300460-01 – Check the heim joint for damage and wear. » If there is damage or wear: – Change the heim joint. 8.13Assembling the piston rod 200574-11 – Clamp the piston rod into a vise with the heim joint. – Mou...

[Page 55] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 53 200571-11 – Mount rebound shim stack  with the smaller shims at the top. – Mount supporting plate . 200570-11 – Mount and tighten nut . Guideline Nut, piston rod M8 30 Nm (22.1 lbf ft) 8.14Assembling the ...

[Page 56] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 54 200587-01 – Fill the damper cartridge about half full. Shock absorber oil (SAE 2.5) (50180342S1) ( p. 437) 200568-11 – Lubricate O-ring  of the seal ring retainer. Lubricant (T158) ( p. 438) – Carefully mount t...

[Page 57] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 55 – Turn adjusting screw  clockwise as far as it will go using an open end wrench. – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-s...

[Page 58] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 56 200271-10 – Position the control lever as shown in the photo. Control lever External tank  is set to Closed, Damper  is set to Vacuum and Oil reservoir  is set to Vacuum. – Activate On/Off switch . The s...

[Page 59] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 57 200267-10 – When the vacuum gauge reaches the required value, turn control lever Oil reser- voir  to Equalize Pressure. Guideline 8 mbar The pressure gauge drops to the required value. 0 bar 200268-10 – When the ...

[Page 60] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 58 200593-01 – Remove adapter  from connector  of the vacuum pump. Info Hold the damper so that the filling port is at the highest location. – Remove the adapter. – Mount and tighten screw . Guideline Screw,...

[Page 61] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 59 8.17Installing the spring 200562-11 – Clamp the damper into the vice with soft jaws. – Measure the overall spring length without a load. – Position the spring. Guideline Spring rate Medium (standard) 95 N/mm (542 ...

[Page 62] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 60 200577-10 – Clamp the shock absorber into the vice with soft jaws. – Remove collar bushing  of the heim joint with a drift. – Turn the shock absorber around and remove collar bushing  of the heim joint with ...

[Page 63] KTM 1190 RC8 R EU/UK 2009

04/SHOCK ABSORBER, SWINGARM 61 200579-11 – Mount lock rings  on both sides. 200578-11 – Mount and grease seal rings  on both sides. Lubricant (T158) ( p. 438) 200582-10 – Push in both collar bushings  of the heim joint. PartShark.com ...

[Page 64] KTM 1190 RC8 R EU/UK 2009

05/EXHAUST 62 9.1Lambda sensor 900007-61 Installation location – The lambda sensor for cylinder 1  is installed in the rear exhaust manifold. – The lambda sensor for cylinder 2  is installed in the front exhaust manifold. 900008-10 Componen...

[Page 65] KTM 1190 RC8 R EU/UK 2009

05/EXHAUST 63 Resistance at: 20 °C (68 °F) 11.7… 14.3 Ω 9.3Removing the exhaust cover completely – Remove the side covers. ( p. 75) 200532-10 – Remove screws . – Remove screws  on both sides. – Take off exhaust cover  completel...

[Page 66] KTM 1190 RC8 R EU/UK 2009

05/EXHAUST 64 200513-10 – Unplug connector  of the lambda sensor (2nd cylinder). Open the cable binder. 200514-10 – Unplug connector  of the lambda sensor (1st cylinder). 200515-10 – Remove screw . Slide the clamp upward. 200516-10 –...

[Page 67] KTM 1190 RC8 R EU/UK 2009

05/EXHAUST 65 200518-10 – Remove nuts . Remove the manifold at the front with the seals. 200519-10 – Remove nuts . Remove the manifold at the rear with the seals. 9.6Installing the exhaust system Info The radiator has only been removed to i...

[Page 68] KTM 1190 RC8 R EU/UK 2009

05/EXHAUST 66 0 0 33 0 0 33 0 0 33 200517-02 – Position the main silencer. Mount and tighten screws  with the washers. Guideline Remaining chassis screws M8 25 Nm (18.4 lbf ft) 200515-11 – Position the clamp. Mount and tighten screw ...

[Page 69] KTM 1190 RC8 R EU/UK 2009

06/AIR FILTER 67 10.1Removing the air filter 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 ...

[Page 70] KTM 1190 RC8 R EU/UK 2009

06/AIR FILTER 68 200499-10 – Remove screws . Take off the retaining plates and holding brackets. – Remove screw . Remove the cover. 200500-10 – Loosen hose clamps . 200501-10 – Loosen the spring-loaded band-type clamp  using the s...

[Page 71] KTM 1190 RC8 R EU/UK 2009

06/AIR FILTER 69 200502-11 – Mount rubber sleeves . Position and tighten the lower hose clamps. Guideline Hose clip, intake flange M4 1.5 Nm (1.11 lbf ft) 200501-11 – Detach the throttle valve body from the handlebar. Mount connector  with ...

[Page 72] KTM 1190 RC8 R EU/UK 2009

07/FUEL TANK, SEAT, TRIM 70 11.1Removing the seat 100669-10 – 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. 11.2Fitting the seat 100730-10 – Po...

[Page 73] KTM 1190 RC8 R EU/UK 2009

07/FUEL TANK, SEAT, TRIM 71 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and co...

[Page 74] KTM 1190 RC8 R EU/UK 2009

07/FUEL TANK, SEAT, TRIM 72 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and co...

[Page 75] KTM 1190 RC8 R EU/UK 2009

07/FUEL TANK, SEAT, TRIM 73 500246-10 – Remove screw . – Take off the fuel tank guard. 11.8Installing the fuel tank guard Info The operations are the same on the left and right sides. 500246-10 – Position the fuel tank guard. – Mount and t...

[Page 76] KTM 1190 RC8 R EU/UK 2009

07/FUEL TANK, SEAT, TRIM 74 Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. – Remove the...

[Page 77] KTM 1190 RC8 R EU/UK 2009

08/MASK, FENDER, DECAL 75 12.1Removing the side covers 200492-10 – Remove screws  on both sides. – Remove side covers  on both sides. Info Watch out for the projections on the inside cover. 12.2Installing the side covers 200492-11 – Posit...

[Page 78] KTM 1190 RC8 R EU/UK 2009

08/MASK, FENDER, DECAL 76 200495-12 – Remove screw . – Remove the screws of the EFI control unit . Unplug and remove the EFI control unit. – Unplug the control unit of the electric starter lock . – Remove the overflow hose. Take off ...

[Page 79] KTM 1190 RC8 R EU/UK 2009

09/FRONT WHEEL 77 13.1Removing the front wheel – Jack up the motorcycle at the rear. ( p. 13) – Jack up the motorcycle at the front. ( p. 10) 100719-10 – Remove the screws  from both brake calipers. – Press back the brake linings with a li...

[Page 80] KTM 1190 RC8 R EU/UK 2009

09/FRONT WHEEL 78 100721-10 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. – Clean screw �...

[Page 81] KTM 1190 RC8 R EU/UK 2009

09/FRONT WHEEL 79 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. 400602-10 – Check the fro...

[Page 82] KTM 1190 RC8 R EU/UK 2009

09/FRONT WHEEL 80 13.5Checking the front brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. 100135-10 – Check the thickness of the brake disc in several p...

[Page 83] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 81 14.1Removing the rear wheel – Jack up the motorcycle at the rear. ( p. 13) 100722-10 – Remove nut . – Remove chain adjuster . – Remove the axle . 100723-01 – Push the rear wheel as far forward as possible and then ...

[Page 84] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 82 100726-01 – 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. 100727-10 – Place the chain adjuster  on the tensioning screw. – Position...

[Page 85] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 83 100726-01 – Push the rear wheel forward as far as possible and place the chain on the rear sprocket. – Pull the rear wheel back and push in the wheel spindle. 100727-10 – Place chain adjuster  on the tensioning screw. – Po...

[Page 86] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 84 14.6Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or g...

[Page 87] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 85 14.8Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ing...

[Page 88] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 86 14.10Checking chain wear 700303-01 – Shift the transmission to neutral. – Pull the lower chain section with specified weight . Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance  of 18 chain li...

[Page 89] KTM 1190 RC8 R EU/UK 2009

10/REAR WHEEL 87 – Install the rear wheel. ( p. 81) PartShark.com 877-999-5686 ...

[Page 90] KTM 1190 RC8 R EU/UK 2009

11/WIRING HARNESS, BATTERY 88 15.1Electric starter lock control unit 900013-01 Installation location – The electric starter lock control unit is located behind the right-hand side cover. Electric starter lock control unit, connector DO ( p. 399) pi...

[Page 91] KTM 1190 RC8 R EU/UK 2009

11/WIRING HARNESS, BATTERY 89 100734-10 – Disconnect negative (minus) cable  of the battery. 100735-10 – Remove the cover of the positive terminal. – Disconnect the positive (plus) cable  of the battery. 100736-10 – Remove screws . �...

[Page 92] KTM 1190 RC8 R EU/UK 2009

11/WIRING HARNESS, BATTERY 90 15.5Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avo...

[Page 93] KTM 1190 RC8 R EU/UK 2009

11/WIRING HARNESS, BATTERY 91 15.6Changing the main fuse 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 main fuse p...

[Page 94] KTM 1190 RC8 R EU/UK 2009

11/WIRING HARNESS, BATTERY 92 100741-10 – 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 (op...

[Page 95] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 93 16.1Brake linings The brake linings fitted by KTM have been tested over long periods and guarantee optimal braking characteristics. The type names of the brake linings are entered in the homologation documents. Info Brake linings a...

[Page 96] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 94 Info Never user 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 d...

[Page 97] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 95 301496-10 – Position the brake caliper. Mount the screws but do not tighten them yet. – Repeat the operation on the opposite side. – Operate the hand brake lever repeatedly until the brake lining presses up against the brake ...

[Page 98] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 96 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 user DOT 5 brake...

[Page 99] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 97 16.8Changing the rear brake linings 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 ...

[Page 100] KTM 1190 RC8 R EU/UK 2009

13/BRAKE SYSTEM 98 301492-10 – Remove locking clip . 301493-10 – Remove bolt . 301494-10 – Remove brake linings . – Remove spring . – Clean the brake caliper. 301495-10 – Position brake linings  and spring . – Mount bo...