KTM 1190 RC8 R EU/UK 2009 Repair Manual

KTM 1190 RC8 R EU/UK 2009

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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

Table of Contents

Table of Contents4
Means of Representation8
Important Notes9
Location of Serial Numbers10
- Vehicle Identification Number/Type Label10
- Key Number10
- Engine Number10
- Fork Part Number10
- Shock Absorber Part Number10
- Steering Damper Part Number11
Motorcycle12
- Jacking up Motorcycle Front12
- Taking Front of Motorcycle off Work Stand12
- Jacking up the Motorcycle in the Middle (Screw-In Type)12
- Removing the Motorcycle from the Work Stand (Screw-In Type)13
- Jacking up the Motorcycle in the Middle (Insertable Type)14
- Removing the Motorcycle from the Work Stand (Insertable Type)14
- Jacking up Motorcycle at the Rear15
- Taking the Rear from the Workstand15
- Starting15
01/Fork, Triple Clamp17
- Adjusting the Compression Damping of the Fork17
- Adjusting the Rebound Damping of the Fork17
- Adjusting the Spring Preload of the Fork18
- Bleeding Fork Legs18
- Vehicle Level19
- Adjusting Front Vehicle Level19
- Removing the Fork20
- Installing the Fork21
- Performing a Fork Service23
- Disassembling the Fork Legs23
- Disassembling the Outer Tubes26
- Checking the Fork Legs27
- Changing the Lower du Bush28
- Assembling the Outer Tubes29
- Assembling the Fork Legs29
02/Handlebar, Controls and Instruments34
- Adjusting Basic Position of Clutch Lever34
- Adjusting the Steering Damper34
- Adjusting the Handlebar Height34
- Adjusting the Play in the Throttle Cable35
- Throttle Grip36
- Changing the Throttle Grip36
- Adjusting the Throttle Cable at the Throttle Valve39
03/Frame42
- Side Stand Switch42
- Footrest Position42
- Adjusting Footrest Position42
- Rear Frame Position43
- Adjusting the Rear Frame Position43
04/Shock Absorber, Swingarm46
- Adjusting the Low-Speed Compression Damping of the Shock Absorber46
- Adjusting the High-Speed Compression Damping of the Shock Absorber46
- Adjusting the Rebound Damping of the Shock Absorber47
- Adjusting the Spring Preload of the Shock Absorber47
- Adjusting the Vehicle Level at the Rear48
- Removing the Shock Absorber48
- Installing the Shock Absorber49
- Servicing the Shock Absorber50
- Removing the Spring50
- Disassembling the Damper51
- Disassembling the Piston Rod52
- Checking the Damper53
- Assembling the Piston Rod54
- Assembling the Damper55
- Bleeding and Filling the Damper57
- Filling the Damper with Nitrogen60
- Installing the Spring61
- Removing the Heim Joint61
- Installing the Heim Joint62
05/Exhaust64
- Lambda Sensor64
- Lambda Sensor Heater64
- Removing the Exhaust Cover Completely65
- Installing the Exhaust Cover Completely65
- Removing the Exhaust System65
- Installing the Exhaust System67
06/Air Filter69
- Removing the Air Filter69
- Installing the Air Filter69
- Removing the Filter Box Bottom69
- Installing the Filter Box Bottom70
07/Fuel Tank, Seat, Trim72
- Removing the Seat72
- Fitting the Seat72
- Removing the Passenger Seat72
- Mounting the Passenger Seat72
- Dismounting the Fuel Tank72
- Installing the Fuel Tank73
- Removing the Fuel Tank Guard74
- Installing the Fuel Tank Guard75
- Checking the Fuel Pressure75
- Checking the Fuel Pressure During the Actuator Test76
08/Mask, Fender, Decal77
- Removing the Side Covers77
- Installing the Side Covers77
- Removing the Inside Cover77
- Installing the Inside Cover78
09/Front Wheel79
- Removing the Front Wheel79
- Installing the Front Wheel79
- Checking the Tire Condition80
- Checking the Tire Pressure81
- Checking the Front Brake Discs82
10/Rear Wheel83
- Removing the Rear Wheel83
- Installing the Rear Wheel83
- Installing the Rear Wheel - When Installing the Engine84
- Checking the Rear Brake Disc85
- Checking for Chain Dirt85
- Cleaning the Chain86
- Checking the Chain Tension86
- Adjusting the Chain Tension87
- Checking Rear Sprocket / Engine Sprocket for Wear87
- Checking Chain Wear88
- Checking Chain Sliding Guard88
- Checking Rear Hub Cush Drive88
11/Wiring Harness, Battery90
- Electric Starter Lock Control Unit90
- Fuel Pump Relay90
- Removing the Battery90
- Installing the Battery91
- Recharging the Battery92
- Changing the Main Fuse93
- Changing the Fuses of Individual Power Consumers93
13/Brake System95
- Brake Linings95
- Checking the Front Brake Linings95
- Changing the Front Brake Linings95
- Checking the Front Brake Fluid Level97
- Adding Front Brake Fluid97
- Adjusting the Basic Position of the Hand Brake Lever98
- Checking the Rear Brake Linings98
- Changing the Rear Brake Linings99
- Checking the Rear Brake Fluid Level101
- Adding Rear Brake Fluid101
- Adjusting the Foot Brake Pedal Stub102
- Adjusting the Foot Brake Pedal102
- Removing the Rear Brake System103
- Installing the Rear Brake System103
14/Light System, Instruments104
- Immobilizer Control Unit104
- Activating/Deactivating Ignition Key104
- Activating the ICU106
- Combination Instrument - Activation of the BOOTLOADER Mode107
- Updating the Combination Instrument Software107
- Setting ROAD or RACE Mode108
- Setting the Clock with SET CLOCK108
- Adjusting Shift Speed RPM1/2108
- Setting the Blank Time of the LAP Button LAP BLANK T109
- Setting the Number of Laps SET NUM LAPS109
- Setting the Fuel Reserve Display TRIPF RESET110
- Setting the Kilometers/Miles SET KM/MILES110
- Setting the Temperature Unit SET °C/°F111
- Switching the External Temperature Display On/Off111
- Resetting Service Display112
- Checking the Headlight Setting112
- Adjust the Headlight Range113
- Changing the Parking Light Bulb113
- Changing the Low Beam Bulb114
- Changing the High Beam Bulb115
30/Engine117
- Removing the Engine117
- Preparing the Engine for Installation119
- Installing the Engine119
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder122
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder123
30/Disassembling the Engine124
- Clamping the Engine into the Engine Work Stand124
- Removing the Engine Bracket124
- Draining the Engine Oil124
- Removing the Front Valve Cover125
- Removing the Rear Valve Cover125
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder125
- Removing the Starter Motor126
- Removing the Oil Filler Tube126
- Removing the Heat Exchanger126
- Removing the Rear Timing Chain Tensioner126
- Removing the Rear Camshaft127
- Removing the Rear Cylinder Head127
- Removing the Rear Piston127
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder128
- Removing the Front Timing Chain Tensioner128
- Removing the Front Camshafts128
- Removing the Front Cylinder Head128
- Removing the Front Piston129
- Removing the Generator Cover129
- Removing the Ignition Pulse Generator129
- Removing the Torque Limiter and Idler130
- Removing the Rotor130
- Removing the Idler and Timing Chain on the Left130
- Removing the Oil Filter131
- Removing the Balancer Shaft131
- Removing the Drive Wheel of the Balancer Shaft131
- Removing the Gear Position Sensor132
- Removing the Left Suction Pump132
- Removing the Water Pump Wheel133
- Removing the Clutch Cover133
- Removing the Idler and Timing Chain on the Right134
- Removing the Clutch Facing134
- Removing the Outer Clutch Hub134
- Removing the Primary Gear135
- Removing the Force Pump135
- Removing the Shift Shaft136
- Removing the Shift Drum Locating136
- Removing the Locking Lever137
- Removing the Left Engine Case137
- Removing the Crankshaft137
- Removing the Middle Suction Pump138
- Removing the Transmission Shaft138
- Removing the Oil Spray Tube139
- Removing the Timing Chain Rails of the Right Engine Case Section139
- Removing the Timing Chain Rails of the Left Engine Case Section139
30/Engine - Work on Individual Parts140
- Work on the Right Section of the Engine Case140
- Removing the Main Bearing of the Right Engine Case Section141
- Selecting the Main Bearing Shells142
- Installing the Right Main Bearing142
- Section ....................................................................... 139 Selecting the Main Bearing Shells142
- Work on the Left Section of the Engine Case143
- Removing the Left Main Bearing145
- Installing the Left Main Bearing145
- Changing the Conrod Bearing146
- Work on the Clutch Cover147
- Changing the Step Bearing of the Crankshaft148
- Checking the Radial Clearance of the Bottom Connecting Rod Bearing149
- Checking/Measuring the Cylinder149
- Checking/Measuring the Piston150
- Checking the Piston Ring End Gap151
- Checking the Piston/Cylinder Mounting Clearance151
- Work on the Cylinder Head151
- Checking the Cylinder Head154
- Work on the Right Idler155
- Checking the Timing Assembly156
- Preparing the Timing Chain Tensioner for Installation156
- Checking the Oil Pressure Regulator Valve157
- Checking the Oil Pumps157
- Checking the Clutch158
- Checking the Shift Mechanism159
- Preassembling the Shift Shaft160
- Dismantling the Main Shaft160
- Dismantling the Countershaft161
- Checking the Transmission162
- Assembling the Main Shaft163
- Assembling the Countershaft163
30/Assembling the Engine165
- Installing the Timing Chain Rails of the Left Engine Case Section165
- Installing the Timing Chain Rails of the Right Engine Case Section165
- Installing the Oil Spray Tube166
- Installing the Transmission Shaft166
- Section ....................................................................... 163 Installing the Oil Spray Tube166
- Installing the Middle Suction Pump167
- Installing the Crankshaft167
- Installing the Left Engine Case168
- Installing the Locking Lever169
- Installing the Shift Drum Locating169
- Installing the Shift Shaft169
- Installing the Force Pump170
- Installing the Left Suction Pump171
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder171
- Installing the Primary Gear172
- Installing the Outer Clutch Hub172
- Installing the Clutch Facing173
- Installing the Idler and Timing Chain on the Right174
- Installing the Clutch Cover174
- Installing the Water Pump Wheel175
- Installing the Gear Position Sensor175
- Installing the Drive Wheel of the Balancer Shaft175
- Installing the Balancer Shaft176
- Installing the Idler and Timing Chain on the Left176
- Installing the Oil Filter177
- Installing the Rotor177
- Installing the Torque Limiter and Idler178
- Installing the Ignition Pulse Generator178
- Installing the Generator Cover178
- Installing the Oil Drain Plug178
- Installing the Rear Piston179
- Installing the Rear Cylinder Head180
- Installing the Rear Camshaft181
- Installing the Rear Timing Chain Tensioner181
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder182
- Installing the Front Piston182
- Installing the Front Cylinder Head184
- Installing the Front Camshafts184
- Installing the Front Timing Chain Tensioner185
- Installing the Heat Exchanger185
- Installing the Oil Filler Tube186
- Installing the Starter Motor186
- Checking the Rear Cylinder Control Time186
- Adjusting the Rear Cylinder Control Time186
- Checking the Rear Valve Clearance187
- Adjusting the Rear Valve Clearance188
- Checking the Front Cylinder Control Time188
- Adjusting the Front Cylinder Control Time188
- Checking the Front Valve Clearance189
- Adjusting the Front Valve Clearance190
- Installing the Front Valve Cover190
- Installing the Rear Valve Cover190
- Mounting the Engine Bracket191
- Dismounting the Engine from the Work Stand191
- Position the Engine Bracket191
- Mount and Tighten Screws and Guideline Screw, Engine Console191
- Screw, Engine Console191
31/Secondary Air System192
- Exhaust Air Injection192
32/Clutch193
- Checking Fluid Level of Hydraulic Clutch193
- Correcting Fluid Level of Hydraulic Clutch193
34/Shift Mechanism194
- Adjusting Shift Lever Stub194
- Adjusting Shift Lever194
- Nm Loctite194
- Nm Loctite195
35/Water Pump, Cooling System196
- Checking the Coolant Level196
- Checking the Antifreeze196
- Removing the Radiator197
- Installing the Radiator197
- Adding Coolant/Bleeding the Cooling System198
- Filling the Cooling System Compensating Tank199
36/Cylinder Head200
- Engine Coolant Temperature Sensor Cylinder 1200
- Engine Coolant Temperature Sensor for Cylinder 2201
- Checking the Valve Clearance202
- Adjusting the Rear Valve Clearance203
- Adjusting the Front Valve Clearance204
- Checking the Rear Cylinder Control Time204
- Checking the Front Cylinder Control Time204
- Adjusting the Rear Cylinder Control Time205
- Adjusting the Front Cylinder Control Time206
- Removing the Rear Camshaft207
- Installing the Rear Camshaft207
- Removing the Front Camshafts208
- Installing the Front Camshafts208
- Installing the Rear Timing Chain Tensioner209
- Installing the Front Timing Chain Tensioner209
38/Lubrication System210
- Oil Circuit210
- Checking the Engine Oil Level211
- Changing the Engine Oil and Filter, Cleaning the Oil Screens211
- Draining Engine Oil, Cleaning Oil Screens211
- (14.8 Lbf Ft)212
- Removing the Oil Filter213
- Installing the Oil Filter214
- Filling up with Engine Oil214
- Adding Engine Oil215
- Checking the Engine Oil Pressure215
- Removing the Oil Jet for the Clutch Lubrication217
- Checking / Cleaning the Oil Jet for Clutch Lubrication218
- Installing the Oil Jet for the Clutch Lubrication218
39/Ignition System220
- Crankshaft Position Sensor220
- Ignition Coil220
41/Throttle Valve Body221
- Throttle Position Sensor Circuit a221
- Throttle Position Sensor Circuit a - Checking in the "Zero" Position221
- Adjusting the Position of the Throttle Position Sensor in Circuit a222
- Removing the Throttle Valve Body to Adjust223
- Reinstalling the Throttle Valve Body When the Adjustments Have Been Made224
- Throttle Position Sensor Circuit B225
- Manifold Absolute Pressure Sensor225
- Connecting the Vacuum Hand Pump to the Manifold Absolute Pressure Sensor226
- Ambient Air Pressure Sensor227
- Injector227
- Rollover Sensor228
- EFI Control Unit229
- Requesting the EFI Control Unit Activation Code229
- Coding the EFI Control Unit229
- Flashing the EFI Control Unit230
Immobilizer Blink Code231
Engine Control Trouble Code240
Connector Overview393
- Motor Drive Circuit a Connector AE393
- Connector AI393
- Crankshaft Position Sensor Connector al393
- Clutch Switch, Connector al393
- Throttle Position Sensor Circuit A, Connector am393
- Throttle Position Sensor Circuit B, Connector am394
- Gear Position Sensor, Connector am394
- Fuel Pump Connector am394
- Wheel Speed Sensor, Connector am394
- Connector AO394
- Diagnostic Connection Plug AP395
- Rollover Sensor Connector AP395
- Throttle Position Sensor Circuit A, Connector AR395
- Throttle Position Sensor Circuit B, Connector AR396
- Fuel Pump Connector AR396
- Side Stand Switch, Connector AR396
- Ignition Coil Cylinder 1 Connector as396
- Ignition Coil Cylinder 2 Connector as396
- CAN Bus Terminating Resistor Connector at397
- Crankshaft Position Sensor, Connector at397
- Clutch Switch Connector at397
- Engine Coolant Temperature Sensor Cylinder 1 Connector AX397
- Throttle Stepper Motor Circuit B, Connector CA397
- Lambda Sensor Cylinder 1, Connector CA398
- Lambda Sensor Cylinder 2, Connector CA398
- Lambda Sensor Cylinder 1, Connector CE398
- Lambda Sensor Cylinder 2, Connector CE398
- Secondary Air Valve Connector CK398
- Connector CM399
- Connector CO399
- Connector CP400
- Connector CQ400
- Connector CU400
- Fuel Evaporation Valve Connector DF401
- Secondary Air Valve Connector DF401
- Electric Starter Lock Control Unit, Connector DN401
- Immobilizer Control Unit, Connector DN401
- Electric Starter Lock Control Unit, Connector DO401
- Immobilizer Control Unit, Connector DO402
- Ambient Air Pressure Sensor Connector DP402
- Manifold Absolute Pressure Sensor Cylinder402
- Connector DP402
- Manifold Absolute Pressure Sensor Cylinder 2 Connector DP402
- Injector Cylinder 1 Connector DQ402
- Injector Cylinder 2 Connector DQ403
- ICU Antenna Connector DV403
- Fuel Pump Relay Connector EB403
- ICU Antenna Connector el403
- Connector EQ403
- Connector er404
- Connector es404
- Connector ET404
- Combination Instrument Connector EV405
- Exhaust Air Injection Valve, Connector FE405
- Fuel Pump Relay406
- CAN Bus Terminating Resistor406
Technical Data - Engine407
- Capacity - Engine Oil407
- Capacity - Coolant408
Engine409
Technical Data - Engine Tightening Torques411
Technical Data - Chassis413
- Lighting Equipment413
- Capacity - Fuel414
Technical Data - Fork415
Technical Data - Shock Absorber416
Technical Data - Chassis Tightening Torques417
Cleaning/Conservation419
- Cleaning Motorcycle419
- Conservation for Winter Operation419
Storage421
- Putting into Operation after Storage421
Service Schedule422
- Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop422
- Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop. (as Additional Job)423
Wiring Diagram424
- Of 3424
- Of 3428
- Of 3434
Operating Substances438
Auxiliary Substances440
Special Tools442
Standards454
Index455

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Owner's Manual242 pages

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KTM 1190 RC8 R EU/UK 2009 Specifications

General

Brand	KTM
Model	1190 RC8 R EU/UK 2009
Category	Motorcycle
Language	English

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