KTM 1190 RC8 R (2008-09) - Service Manual / Repair Manual - Wiring Diagrams - Owners Manual

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KTM 1190 RC8 R (2008-09) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual, Owners Manual and Wiring Diagrams, to motorcycles KTM 1190 RC8 R (2008-09).

 
CONTENTS:

KTM 1190 RC8 SERVICE MANUAL (2008)
KTM 1190 RC8 R SERVICE MANUAL (2009)
KTM 1190 RC8 SETUP INSTUCTIONS (2008)
KTM 1190 RC8 R SETUP INSTUCTIONS (2013)
KTM 1190 RC8 OWNERS MANUAL (USA) (2008)
KTM 1190 RC8 R OWNERS MANUAL (2009)


INDEX SERVICE MANUAL:

Means Of Representation
Important Notes
Location Of Serial Numbers
- Chassis number/type label
- Key number
- Engine number
- Fork part number
- Shock absorber part number
- Steering damper part number
Motorcycle
- Jacking up motorcycle front
- Taking front of motorcycle off work stand
- Jacking up motorcycle rear
- Taking rear of motorcycle off work stand
- Starting
01/Fork, Triple Clamp
- Adjusting compression damping of fork
- Adjusting rebound damping of fork
- Adjusting spring preload of fork
- bleeding fork legs
- Vehicle level
- Adjusting front vehicle level
02/Handlebar, Controls And Instruments
- Adjusting basic position of clutch lever
- Adjusting the steering damper
- Adjusting the handlebar height
- Adjusting gas Bowden cable
03/Frame
- Footrest position
- Adjusting footrest position
- Rear frame position
- Adjusting the rear frame position
04/Shock Absorber, Swingarm
- Adjusting the low-speed compression damping of the shock absorber
- Adjusting high-speed compression damping of the shock absorber
- Adjusting rebound damping of the shock absorber
- Adjusting spring preload of shock absorber
- Adjusting the vehicle level at the rear
05/Exhaust
- Removing the exhaust cover completely
- Installing the exhaust cover completely
- Removing the exhaust system
- Installing the exhaust system
06/Air Filter
- Removing the air filter
- Installing the air filter
- Removing the filter box bottom
- Installing the filter box bottom
07/Fuel Tank, Seat, Trim
- Removing the seat
- Fitting the seat
- Removing passenger seat
- Fitting the passenger seat
- Dismounting the fuel tank
- Installing the fuel tank
- Removing the fuel tank guard
- Installing the fuel tank guard
08/Mask, Fender, Decal
- Removing the side covers
- Installing the side covers
- Removing the inside cover
- Installing the inside cover
09/Front Wheel
- Removing front wheel
- Fitting front wheel
- Tire condition checking
- Checking tire air pressure
- Checking the front brake discs
10/Rear Wheel
- Removing rear wheel
- Installing the rear wheel
- Installing the rear wheel - when installing the engine
- Tire condition checking
- Checking tire air pressure
- Checking the rear brake disc
- Checking for chain dirt
- Cleaning the chain
- Checking the chain tension
- Adjusting the chain tension
- Checking rear sprocket / engine sprocket for wear
- Checking chain wear
- Checking chain sliding guard
- Checking rear hub shock absorbers
11/Wiring Harness, Battery
- Removing the battery
- Installing the battery
- Recharging the battery
- Changing the main fuse
- Changing the fuses of individual power consumers
13/Brake System
- Brake linings
- Checking the front brake linings
- Checking brake fluid level of front brake
- Topping up brake fluid of front brake
- Adjusting the basic position of the handbrake lever
- Checking the rear brake linings
- Checking rear brake fluid level
- Topping up rear brake fluid
- Adjusting the footbrake pedal stub
- Adjusting the footbrake pedal
- Removing the rear brake system
- Installing the rear brake system
14/Light System, Instruments
- Activating/deactivating ignition key
- Setting ROAD or RACE mode
- Setting the clock with SET CLOCK
- Adjusting shift speed RPM1/2
- Setting the blank time of the LAP button LAP BLANK T
- Setting number of laps SET NUM LAPS
- Setting fuel reserve display TRIPF RESET
- Setting kilometers/miles SET KM/MILES
- Setting temperature unit SET °C/°F
- Switching external temperature display on/off
- Resetting the Service display
- Checking headlight adjustment
- Adjusting headlamp range
- Changing the parking light bulb
- Changing the low beam bulb
- Change the high beam bulb.
30/Engine
- Removing the engine
- Preparing the engine for installation
- Installing the engine
- Setting the engine to ignition top dead center of the rear cylinder
- Setting the engine to ignition top dead center of the front cylinder
30/Disassembling The Engine
- Clamping the engine into the engine work stand
- Draining the engine oil
- Removing the front valve cover
- Removing the rear valve cover
- Setting the engine to ignition top dead center of the rear cylinder
- Removing the starter motor
- Removing the oil filler tube
- Removing the heat exchanger
- Removing the rear timing chain tensioner
- Removing the rear camshaft
- Removing the rear cylinder head
- Removing the rear piston
- Setting the engine to ignition top dead center of the front cylinder
- Removing the front timing chain tensioner
- Removing the front camshafts
- Removing the front cylinder head
- Removing the front piston
- Removing the generator cover
- Removing the ignition pulse generator
- Removing the torque limiter and idler
- Removing the rotor
- Removing the idler and timing chain on the left
- Removing the oil filter
- Removing the balancer shaft
- Removing the drive wheel of the balancer shaft
- Removing the gear position sensor
- Removing the left suction pump
- Removing the water pump wheel
- Removing the clutch cover
- Removing the idler and timing chain on the right
- Removing the clutch facing
- Removing the outer clutch hub
- Removing the primary gear
- Removing the force pump
- Removing the shift shaft
- Removing the shift drum locating
- Removing the locking lever
- Removing the left engine case
- Removing the crankshaft
- Removing the middle suction pump
- Removing the transmission shaft
- Removing the oil spray tube
- Removing the timing chain rails of the right engine case section
- Removing the timing chain rails of the left engine case section
30/Engine - Work On Individual Parts
- Work on the right section of the engine case
- Removing the main bearing of the right engine case section
- Selecting the main bearing shells
- Installing the right main bearing
- Work on the left section of the engine case
- Removing the left main bearing
- Installing the left main bearing
- Changing the conrod bearing
- Work on the clutch cover
- Changing the step bearing of the crankshaft
- Checking the radial clearance of the bottom connecting rod bearing
- Checking/measuring the cylinder
- Checking/measuring the piston
- Checking the piston ring
- Checking the piston/cylinder mounting clearance
- Work on the cylinder head
- Checking the cylinder head
- Work on the right idler
- Checking the timing assembly
- Preparing the timing chain tensioner for installation
- Checking the oil pressure regulator valve
- Checking the oil pumps
- Checking the clutch
- Checking the shift mechanism
- Preassembling the shift shaft
- Dismantling the main shaft
- Dismantling the countershaft
- Checking the transmission
- Assembling the main shaft
- Assembling the countershaft
30/Assembling The Engine
- Installing the timing chain rails of the left engine case section
- Installing the timing chain rails of the right engine case section
- Installing the oil spray tube
- Installing the transmission shaft
- Installing the middle suction pump
- Installing the crankshaft
- Installing the left engine case
- Installing the locking lever
- Installing the shift drum locating
- Installing the shift shaft
- Installing the force pump
- Installing the left suction pump
- Setting the engine to ignition top dead center of the rear cylinder
- Installing the primary gear
- Installing the outer clutch hub
- Installing the clutch facing
- Installing the idler and timing chain on the right
- Installing the clutch cover
- Installing the water pump wheel
- Installing the gear position sensor
- Installing the drive wheel of the balancer shaft
- Installing the balancer shaft
- Installing the idler and timing chain on the left
- Installing the oil filter
- Installing the rotor
- Installing the torque limiter and idler
- Installing the ignition pulse generator
- Installing the generator cover
- Installing the oil drain plug
- Installing the rear piston
- Installing the rear cylinder head
- Installing the rear camshaft
- Installing the rear timing chain tensioner
- Setting the engine to ignition top dead center of the front cylinder
- Installing the front piston
- Installing the front cylinder head
- Installing the front camshafts
- Installing the front timing chain tensioner
- Installing the heat exchanger
- Installing the oil filler tube
- Installing the starter motor
- Checking the rear valve clearance
- Adjusting the rear valve clearance
- Checking the front valve clearance
- Adjusting the front valve clearance
- Installing the front valve cover
- Installing the rear valve cover
32/Clutch
- Checking fluid level of hydraulic clutch
- Correcting fluid level of hydraulic clutch
34/Shift Mechanism
- Adjusting shift lever stub
- Adjusting shift lever
35/Water Pump, Cooling System
- Checking the coolant level
- Checking the antifreeze
- Removing the radiator
- Installing the radiator
- Adding coolant/bleeding the cooling system
- Filling the cooling system compensating tank
36/Cylinder Head
- Checking the valve clearance
- Adjusting the rear valve clearance
- Adjusting the front valve clearance
- Removing the rear camshaft
- Installing the rear camshaft
- Removing the front camshafts
- Installing the front camshafts
- Removing the rear timing chain tensioner
- Installing the rear timing chain tensioner
- Removing the front timing chain tensioner
- Installing the front timing chain tensioner
38/Lubrication System
- Oil circuit
- Checking engine oil level
- Changing engine oil and filter, cleaning oil screen
- Draining engine oil, cleaning oil screens
- Removing oil filter
- Fitting oil filter
- Filling up with engine oil
- Topping up engine oil
Immobilizer Flash Code
Engine Control Error Code
Technical Data - Engine
- Capacity- engine oil
- Capacity - coolant
Technical Data - Tolerance, Wear Limits Of Engine
Technical Data - Engine Tightening Torques
Technical Data - Chassis
- Lighting equipment
- Capacity - fuel
Technical Data - Fork
Technical Data - Shock Absorber
Technical Data - Chassis Tightening Torques
Cleaning/Conservation
- Cleaning motorcycle
- Conservation for winter operation
Storage
- Storage
- Putting into operation after storage
Greasing And Service Table
Substances
Auxiliary Substances
Special Tools
Standards
Index