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30/DISASSEMBLING THE ENGINE 89

200416-10

– Remove external rotor  and internal rotor .

– Remove pin .

– Remove pins .

19.35Removing the shift shaft

200417-10

– Push sliding plate  away from the shift drum locating . Remove shift shaft 

with the washer.

19.36Removing the shift drum locating

200418-10

– Remove screw .

– Press locking lever  away from shift drum locating  and take off the shift drum

locating.

– Release the locking lever.

19.37Removing the locking lever

200420-10

– Remove screw .

– Take off locking lever  with the sleeve and spring.

Table of Contents4
Means of Representation7
Important Notes8
Location of Serial Numbers9
- Chassis Number/Type Label9
- Key Number9
- Engine Number9
- Fork Part Number9
- Shock Absorber Part Number9
- Steering Damper Part Number10
Motorcycle11
- Jacking up Motorcycle Front11
- Taking Front of Motorcycle off Work Stand11
- Jacking up Motorcycle Rear11
- Taking Rear of Motorcycle off Work Stand11
- Starting12
01/Fork, Triple Clamp13
- Adjusting Compression Damping of Fork13
- Adjusting Rebound Damping of Fork13
- Adjusting Spring Preload of Fork14
- Bleeding Fork Legs14
- Vehicle Level15
- Adjusting Front Vehicle Level15
02/Handlebar, Controls and Instruments17
- Adjusting Basic Position of Clutch Lever17
- Adjusting the Steering Damper17
- Adjusting the Handlebar Height17
- Adjusting Gas Bowden Cable18
03/Frame19
- Footrest Position19
- Adjusting Footrest Position19
- Rear Frame Position20
- Adjusting the Rear Frame Position20
04/Shock Absorber, Swingarm23
- Adjusting the Low-Speed Compression Damping of the Shock Absorber23
- Adjusting High-Speed Compression Damping of the Shock Absorber23
- Adjusting Rebound Damping of the Shock Absorber24
- Adjusting Spring Preload of Shock Absorber24
- Adjusting the Vehicle Level at the Rear25
05/Exhaust26
- Removing the Exhaust Cover Completely26
- Installing the Exhaust Cover Completely26
- Removing the Exhaust System26
- Installing the Exhaust System28
06/Air Filter30
- Removing the Air Filter30
- Installing the Air Filter30
- Removing the Filter Box Bottom30
- Installing the Filter Box Bottom32
07/Fuel Tank, Seat, Trim34
- Removing the Seat34
- Fitting the Seat34
- Removing Passenger Seat34
- Fitting the Passenger Seat34
- Dismounting the Fuel Tank34
- Installing the Fuel Tank35
- Removing the Fuel Tank Guard36
- Installing the Fuel Tank Guard37
08/Mask, Fender, Decal38
- Removing the Side Covers38
- Installing the Side Covers38
- Removing the Inside Cover38
- Installing the Inside Cover39
09/Front Wheel40
- Removing Front Wheel40
- Fitting Front Wheel40
- Tire Condition Checking41
- Checking Tire Air Pressure41
- Checking the Front Brake Discs42
10/Rear Wheel43
- Removing Rear Wheel43
- Installing the Rear Wheel43
- Installing the Rear Wheel - When Installing the Engine44
- Tire Condition Checking46
- Checking Tire Air Pressure46
- Checking the Rear Brake Disc47
- Checking for Chain Dirt47
- Cleaning the Chain47
- Checking the Chain Tension47
- Adjusting the Chain Tension48
- Checking Rear Sprocket / Engine Sprocket for Wear49
- Checking Chain Wear49
- Checking Chain Sliding Guard49
- Checking Rear Hub Shock Absorbers49
11/Wiring Harness, Battery51
- Removing the Battery51
- Installing the Battery51
- Recharging the Battery52
- Changing the Main Fuse53
- Changing the Fuses of Individual Power Consumers54
13/Brake System55
- Brake Linings55
- Checking the Front Brake Linings55
- Checking Brake Fluid Level of Front Brake55
- Topping up Brake Fluid of Front Brake56
- Adjusting the Basic Position of the Handbrake Lever56
- Checking the Rear Brake Linings56
- Checking Rear Brake Fluid Level57
- Topping up Rear Brake Fluid57
- Adjusting the Footbrake Pedal Stub58
- Adjusting the Footbrake Pedal58
- Removing the Rear Brake System59
- Installing the Rear Brake System59
14/Light System, Instruments60
- Activating/Deactivating Ignition Key60
- Setting ROAD or RACE Mode61
- Setting the Clock with SET CLOCK62
- Adjusting Shift Speed RPM1/262
- Setting the Blank Time of the LAP Button LAP BLANK T63
- Setting Number of Laps SET NUM LAPS63
- Setting Fuel Reserve Display TRIPF RESET64
- Setting Kilometers/Miles SET KM/MILES64
- Setting Temperature Unit SET °C/°F65
- Switching External Temperature Display On/Off65
- Resetting the Service Display65
- Checking Headlight Adjustment66
- Adjusting Headlamp Range66
- Changing the Parking Light Bulb67
- Changing the Low Beam Bulb68
- Change the High Beam Bulb69
30/Engine72
- Removing the Engine72
- Preparing the Engine for Installation74
- Installing the Engine74
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder78
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder78
30/Disassembling the Engine79
- Clamping the Engine into the Engine Work Stand79
- Draining the Engine Oil79
- Removing the Front Valve Cover79
- Removing the Rear Valve Cover79
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder80
- Removing the Starter Motor80
- Removing the Oil Filler Tube80
- Removing the Heat Exchanger81
- Removing the Rear Timing Chain Tensioner81
- Removing the Rear Camshaft81
- Removing the Rear Cylinder Head82
- Removing the Rear Piston82
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder82
- Removing the Front Timing Chain Tensioner82
- Removing the Front Camshafts83
- Removing the Front Cylinder Head83
- Removing the Front Piston83
- Removing the Generator Cover84
- Removing the Ignition Pulse Generator84
- Removing the Torque Limiter and Idler84
- Removing the Rotor84
- Removing the Idler and Timing Chain on the Left85
- Removing the Oil Filter86
- Removing the Balancer Shaft86
- Removing the Drive Wheel of the Balancer Shaft86
- Removing the Gear Position Sensor86
- Removing the Left Suction Pump87
- Removing the Water Pump Wheel88
- Removing the Clutch Cover88
- Removing the Idler and Timing Chain on the Right88
- Removing the Clutch Facing89
- Removing the Outer Clutch Hub89
- Removing the Primary Gear90
- Removing the Force Pump90
- Removing the Shift Shaft91
- Removing the Shift Drum Locating91
- Removing the Locking Lever91
- Removing the Left Engine Case92
- Removing the Crankshaft92
- Removing the Middle Suction Pump92
- Removing the Transmission Shaft93
- Removing the Oil Spray Tube94
- Removing the Timing Chain Rails of the Right Engine Case Section94
- Removing the Timing Chain Rails of the Left Engine Case Section94
30/Engine - Work on Individual Parts95
- Work on the Right Section of the Engine Case95
- Removing the Main Bearing of the Right Engine Case Section96
- Selecting the Main Bearing Shells97
- Installing the Right Main Bearing97
- Work on the Left Section of the Engine Case98
- Removing the Left Main Bearing100
- Installing the Left Main Bearing100
- Changing the Conrod Bearing101
- Work on the Clutch Cover102
- Changing the Step Bearing of the Crankshaft103
- Checking the Radial Clearance of the Bottom Connecting Rod Bearing104
- Checking/Measuring the Cylinder104
- Checking/Measuring the Piston105
- Checking the Piston Ring End Gap106
- Checking the Piston/Cylinder Mounting Clearance106
- Work on the Cylinder Head106
- Checking the Cylinder Head109
- Work on the Right Idler110
- Checking the Timing Assembly111
- Preparing the Timing Chain Tensioner for Installation111
- Checking the Oil Pressure Regulator Valve112
- Checking the Oil Pumps112
- Checking the Clutch113
- Checking the Shift Mechanism114
- Preassembling the Shift Shaft115
- Dismantling the Main Shaft115
- Dismantling the Countershaft116
- Checking the Transmission117
- Assembling the Main Shaft118
- Assembling the Countershaft118
30/Assembling the Engine120
- Installing the Timing Chain Rails of the Left Engine Case Section120
- Installing the Timing Chain Rails of the Right Engine Case Section120
- Installing the Oil Spray Tube121
- Installing the Transmission Shaft121
- Installing the Middle Suction Pump122
- Installing the Crankshaft122
- Installing the Left Engine Case123
- Installing the Locking Lever124
- Installing the Shift Drum Locating124
- Installing the Shift Shaft124
- Installing the Force Pump125
- Installing the Left Suction Pump126
- Setting the Engine to Ignition Top Dead Center of the Rear Cylinder126
- Installing the Primary Gear127
- Installing the Outer Clutch Hub127
- Installing the Clutch Facing128
- Installing the Idler and Timing Chain on the Right129
- Installing the Clutch Cover129
- Installing the Water Pump Wheel130
- Installing the Gear Position Sensor130
- Installing the Drive Wheel of the Balancer Shaft130
- Installing the Balancer Shaft131
- Installing the Idler and Timing Chain on the Left131
- Installing the Oil Filter132
- Installing the Rotor132
- Installing the Torque Limiter and Idler133
- Installing the Ignition Pulse Generator133
- Installing the Generator Cover133
- Installing the Oil Drain Plug133
- Installing the Rear Piston134
- Installing the Rear Cylinder Head135
- Installing the Rear Camshaft136
- Installing the Rear Timing Chain Tensioner136
- Setting the Engine to Ignition Top Dead Center of the Front Cylinder137
- Installing the Front Piston137
- Installing the Front Cylinder Head139
- Installing the Front Camshafts139
- Installing the Front Timing Chain Tensioner140
- Installing the Heat Exchanger140
- Installing the Oil Filler Tube141
- Installing the Starter Motor141
- Checking the Rear Valve Clearance141
- Adjusting the Rear Valve Clearance142
- Checking the Front Valve Clearance142
- Adjusting the Front Valve Clearance142
- Installing the Front Valve Cover143
- Installing the Rear Valve Cover143
32/Clutch144
- Checking Fluid Level of Hydraulic Clutch144
- Correcting Fluid Level of Hydraulic Clutch144
34/Shift Mechanism145
- Adjusting Shift Lever Stub145
- Adjusting Shift Lever145
35/Water Pump, Cooling System147
- Checking the Coolant Level147
- Checking the Antifreeze147
- Removing the Radiator148
- Installing the Radiator148
- Adding Coolant/Bleeding the Cooling System149
- Filling the Cooling System Compensating Tank150
36/Cylinder Head151
- Checking the Valve Clearance151
- Adjusting the Rear Valve Clearance152
- Adjusting the Front Valve Clearance152
- Removing the Rear Camshaft153
- Installing the Rear Camshaft153
- Removing the Front Camshafts154
- Installing the Front Camshafts154
- Removing the Rear Timing Chain Tensioner154
- Installing the Rear Timing Chain Tensioner155
- Removing the Front Timing Chain Tensioner155
- Installing the Front Timing Chain Tensioner155
38/Lubrication System156
- Oil Circuit156
- Checking Engine Oil Level157
- Changing Engine Oil and Filter, Cleaning Oil Screen157
- Draining Engine Oil, Cleaning Oil Screens157
- Removing Oil Filter159
- Fitting Oil Filter160
- Filling up with Engine Oil160
- Topping up Engine Oil161
Immobilizer Flash Code162
Engine Control Error Code163
Technical Data - Engine165
- Capacity- Engine Oil165
- Capacity - Coolant165
Technical Data - Tolerance, Wear Limits of Engine166
Technical Data - Engine Tightening Torques168
Technical Data - Chassis170
- Lighting Equipment171
- Capacity - Fuel171
Technical Data - Fork172
Technical Data - Shock Absorber173
Technical Data - Chassis Tightening Torques174
Cleaning/Conservation176
- Cleaning Motorcycle176
- Conservation for Winter Operation176
Storage177
- Putting into Operation after Storage177
Greasing and Service Table178
- Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop178
- Important Service Tasks to be Carried out by an Authorized KTM-RC8 Workshop. (as Additional Job)179
Wiring Diagram180
- Of 3180
- Of 3184
- Of 3190
Substances194
Auxiliary Substances196
Special Tools197
Standards205
Index206

Brand	KTM
Model	1190 RC8 EU 2008
Category	Motorcycle
Language	English

KTM 1190 RC8 EU 2008 User Manual

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