1190 RC8 USA 2008 SPARE PARTS MANUAL: ENGINE ENGLISH ART.NO.: 3CM089851HEN

Transcription

1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM089851HEN ENGLISH

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3 INDEX SPECIAL TOOLS ENGINE CASE CLUTCH COVER BALANCER SHAFT 3x 4x 5x 6x CYLINDER CRANKSHAFT, PISTON SECONDARY AIR SYSTEM SAS CLUTCH 7x 8x 9x 10x TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM WATER PUMP 11x 12x 13x 15x 1

4 INDEX COOLING SYSTEM VALVE DRIVE TIMING DRIVE CYLINDER HEAD REAR 16x 17x 18x 19x CYLINDER HEAD FRONT LUBRICATING SYSTEM IGNITION SYSTEM ELECTRIC STARTER THROTTLE BODY 2 20x 25x 21x 23x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. 24x

5 SPECIAL TOOLS UNIVERSAL MOUNTING RACK ENGINE BRACKET CLUTCH HOLDER MOUNT. SLEEVE SHAFT SEAL RING PRESSING TOOL D53 MAIN BEARING BEARING RING F. PRESSING TOOL PULLER CPL. F. IGNITION COVER RING F. COMB. SHAFT BEARING ARBOR PRESS SS-RING DRIVE ENGINE BLOCKING SCREW PRES.SOCKET COUNTERSHAFT DRIVE PULLER F. COUNTERSHAFT DRIVE COMBINATION PRESSURE PAD EXTENSION TORQUE WRENCH UNLOCKING TOOL PRES. PEACE F. ROTOR EXTRACTOR MAGNETO EXTRACTOR FRAME SUPPORT CENTERING PIN / C * NEW PART X AS REQUIRED 3

6 ENGINE CASE ENGINE CASE CPL. WITH BEARINGS INT. TORX FLAT HEAD M 5X BRACKET FOR BEARING INSERT HH COLLAR SCREW M8X30 TX ENGINE BRACKET R/S MOLDED RING CASE CENTER HH COLLAR SCREW M 5X16 WS= OILFILTER CAP O-RING 39,34X2,62 NBR 70 SH HH COLLAR SCREW M6X25 TX PINION COVER CPL CHAIN FAIL. PROTECTION CPL CYL.ROLLER BEAR. NJ202 ECP C SWING BEARING OUTSIDE LC DOWEL 20,1X24X DOWEL 9,8 X 7 X STUD M6X HH COLLAR SCREW M 6X80 WS= CASE SCREW M8X125 AS HH COLLAR SCREW M 6X90 WS= HH COLLAR SCREW M 6X50 WS= REDUCING JET "30" M6X0, O-RING 9X1,5 NBR SCREW PLUG PLUG DIN0913-M10X1X INT. TORX OVAL HEAD M 5X MAIN JET SLS-VALVE COPPER GASK.DIN7603-8,2X13X HH COLLAR SCREW M8X16 TX GASKET SET ENGINE CPL / C * NEW PART X AS REQUIRED 4

7 CLUTCH COVER OUTER CLUTCH COVER MOLDED RING OUTER CLUTCH COVER CLUTCH CASE WITH BEARINGS CLUTCH COVER GASGET DOWEL 9,8 X 7 X HH COLLAR SCREW M 6X95 WS= HH COLLAR SCREW M 6X30 SW= HH COLLAR SCREW M 6X90 WS= HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X35 WS= HH COLLAR SCREW M8X16 TX SEAL RING 8X14X1 AI / C * NEW PART X AS REQUIRED 5

8 BALANCER SHAFT STOP DISK 15,2X25X BEARING BOLT 15X NEEDLE BEARING K 15X19X BALANCER SHAFT L/S / C * NEW PART X AS REQUIRED 6

9 CYLINDER CYLINDER BASE GASGET CYLINDER GROOVED PIN DIN1474 5X / C * NEW PART X AS REQUIRED 7

10 CRANKSHAFT, PISTON CONNECTING-ROD SCREW MJ10X NEEDLE ROL.DIN5402 NRB 4X9, CONNECTING-ROD SPLIT BEAR. BUSH RED 08 x SPLIT BEAR. BUSH BLUE 08 x SPLIT BEAR. BUSH YELLOW 08 x WOODRUFF KEY DIN6888 4X5X SPLIT BEAR. BUSH RED 08 x SPLIT BEAR. BUSH BLUE 08 x SPLIT BEAR. BUSH YELLOW 08 x CRANKSHAFT CPL BUSHING BOWL 28X32X HH-NUT M33X1,5 L/S WS WASHER 33,2X46X I PISTON SIZE 1 x II PISTON SIZE 2 x PISTON PIN D= CIRCLIP PRIMARY GEAR DRIVE WHEEL BALANCER SHAFT L-RING PISTON RING MN PISTON RING GFSOE / C * NEW PART X AS REQUIRED 8

11 SECONDARY AIR SYSTEM SAS CONTROL VALVE SAS SAS HOSE-CYLINDER FRONT SAS HOSE-CYLINDER REAR SAS HOSE-AIR FILTER BOX SAS-FLANGE SLS-VALVE VARIABLE ONE-EAR CLAMP 22,6MM VARIABLE ONE-EAR CLAMP 21,0MM CLAMP STD DN SAS-SUPPORT RC RANGE CHANGE METAL NUT M HH COLLAR SCREW M5x12 TX HH COLLAR SCREW M 6X12 WS= / C * NEW PART X AS REQUIRED 9

12 CLUTCH AH SCREW DIN7984-M 6X SPRING RETAINER STEPPED CLUTCH SPRING D2,7/35MM PINK PRESSURE CAP BALL BEARING 6003 JR2 C LINING DISK OUTSIDE 3MM STEEL DISK 2MM LINING DISK 3MM LINING DISK INSIDE 3,8MM BELLEVILLE SPRING BEARING RING HEXAGON NUT DIN0936-M22X1,5 R PULLEY 22X39X3MM CLUTCH BOOSTER UNIT CPL CLUTCH TAPPET CPL SECTION WASHER CLUTCH CAGE CPL OIL PUMP GEAR WHEEL 32-T NEEDLE BUSH HK 30X35X STOP DISK 30,2/50/ PUSH ROD CPL. 2-PARTS COPPER GASKET DIN X14X HOLLOW SCREW CPL. M 10X1 ' PUSH ROD GUIDE DISTANCE PLATE 7MM HH COLLAR SCREW M6X50 TX CYLINDER CPL. LC HH COLLAR SCREW M 6X25 WS= DISTANCE CLUTCH CONTR. CPL O-RING GASKET SHAFT SEAL RING 9X18X06 B-NBR SLEEVE CLUTCH CONTR / C * NEW PART X AS REQUIRED 10

13 TRANSMISSION I - MAIN SHAFT BALL BEARING 6206 C3 J1 NSK MAIN SHAFT 14T NEEDLE BUSH HK0912 9/13/ NEEDLE BEAR. K IDLER GEAR 5.G STOP DISK 27,9/35,75/1, LOCK RING DIN5417-WS SLIDING GEAR 3./4.G STOP DISK 22,2/30,2/1, NEEDLE BEAR. K 22X26X13 TN IDLER GEAR 6.G SOLID GEAR 2.G BALL BEARING 6204 DU J1 C STOP DISK 20,2X28X1,5 x STOP DISK 20,2/28/1,6 x STOP DISK 20,2/28/1,7 x STOP DISK 20,2/28/1,8 x STOP DISK 20,2/28/1,9 x STOP DISK 20,2/28/2,0 x STOP DISK 20,2/28/2,1 x STOP DISK 20,2/28/2,2 x / C * NEW PART X AS REQUIRED 11

14 TRANSMISSION II - COUNTERSHAFT CIRCLIP DIN471 20X1, STOP DISK 20,2X28X1, BALL BEARING 6204 J1 C IDLER GEAR 1.G NEEDLE BEAR. K 24X28X13 TN STOP DISK 24,3/35,75/ SLIDING GEAR 5.G LOCK RING WS STOP DISK 27/36/1, IDLER GEAR 4.G NEEDLE BEAR. K IDLER GEAR 3.G SLIDING GEAR 6.G CIRCLIP DIN X1,5 NIRO STOP DISK 29,9/39/1, IDLER GEAR 2.G COUNTER SHAFT CYL.ROLLER BEAR.NJ206 ET2XCS SH.SEAL RING 30X47X7 BSL VITON CHAIN SPROCKET 16-T 03 x CHAIN SPROCKET 17-T 03 x CHAIN SPROCKET 17-T DAMPED 03 x SECURING PLATE TOOTHED HEXAGON NUT M20X1, STOP DISK 20,2 X 34 X / C * NEW PART X AS REQUIRED 12

15 SHIFTING MECHANISM NEEDLE BEAR.HK X20X SHIFT SHAFT CPL TENSIONING SPRING 0,8MM SHAFT SEAL RING 14X24X6 B RETURN SPRING 2,2MM ' SPRING GUIDE STOP DISK 14X30X PRESSURE SPRING 0,9MM SHIFT RAIL 11,8X105MM SHIFTING ROLLER 6X8X5, SHIFTING FORK SHIFTING FORK HH COLLAR SCREW M 6X20 WS= LOCKING LEVER CPL SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING AH SCREW DIN6912 M6X SHIFT DRUM LOCATING CPL BALL BEARING C SHIFTING FORK GROOVED BALL BEARING 6808 JRC SHIFT ROLLER CPL CONTACT SPRING CONTACT BOLT O-RING 27,5X2,5 NBR AH SCREW DIN0912-M 6X GEAR-POSITION SENSOR COLLAR BUSHING 6X8X12X GROOVED BALL BEAR RS C SHIFTING LEVER CPL RUBBER FOR SHIFT LEVER STEP PLATE SHIFTING LEVER AH SCREW DIN0912-M 6X S HH COLLAR SCREW M6X16 ISA SHIFT ROD CPL SPECIAL WASHER 6,4X21,4X2, / C * NEW PART X AS REQUIRED 13

16 SHIFTING MECHANISM HH COLLAR SCREW M6X25 TX SPECIAL WASHER D=26X3 ALU ELO S HH COLLAR SCREW M8X30 TX SPECIAL SCREW M6X19 WS= PAIR OF WASHERS M 6 NORDLOCK STEEL WASHER 6,4X17X S RESERVE GEAR CHANGE KIT SELF LOCKING NUT M / C * NEW PART X AS REQUIRED 14

17 WATER PUMP HH COLLAR SCREW M 6X10 WS= WATER PUMP COVER MOLDED RING WATER PUMP COV HH COLLAR SCREW M 6X13 WS= WATER PUMP ROTOR FORM WASHER 16X1 NIRO WEAR BUSHING WITH SEAL RING HH COLLAR SCREW M 6X45 WS= HH COLLAR SCREW M 6X25 WS= O-RING 5,0X1,2 NBR DOWEL 6X8X11, O-RING 9X1,5 NBR SHAFT SEAL RING 15/30/4,5 BAUD CIRCLIP DIN X1,2 NIRO CYL.ROLLER BEAR. NJ202 ECP C / C * NEW PART X AS REQUIRED 15

18 COOLING SYSTEM COOLER "VW1585" CPL RADIATOR CAP 1,4 BAR HH COLLAR SCREW M6X12 TX ALU-GASKET 6X10X THERMOSWITCH LC8 102DG ' O-RING 17X1,5 NB SPECIAL SCREW M6X21 WS= RUBBER SLEEVE D=12MM RADIATOR HOSE CPL. CYL.-FRONT RADIATOR HOSE CPL. CYL.-REAR PREFORMED HOSE COOLER/WAPU HOSE CLAMP SGT HOSE CLAMP GEMI MM VARIABLE ONE-EAR CLAMP 33,1MM PREFORMED HOSE COOLER INLET WATER PIPE CYL. REAR WATER PIPE CYL. FRONT PREFORMED HOSE CYL. REAR PREFORMED HOSE CYL. FRONT EXPANSION TANK CPL HOSE 6X10 EPDM 03 x YDNAC-CLAMP MM PLUG F. EXPANSION TANK HH COLLAR SCREW M6X13 TX HOSE CLAMP 19/25 CPL HH COLLAR SCREW M 6X25 WS= THERMOSTAT 70 DEGREE HH COLLAR SCREW M6X15 TX FAN CLACK RUBBER FAN COWL WITH FAN RUBBER SLEEVE D=8MM OPEN SPECIAL SCREW M5X / C * NEW PART X AS REQUIRED 16

19 VALVE DRIVE VALVE LEVER SHAFT VALVE LEVER SHIM D=10/2,00 03 x SHIM D=10/2,05 03 x SHIM D=10/2,10 03 x SHIM D=10/2,15 03 x SHIM D=10/2,20 03 x SHIM D=10/2,25 03 x SHIM D=10/2,30 03 x SHIM D=10/2,35 03 x SHIM D=10/2,40 03 x SHIM D=10/2,45 03 x SHIM D=10/2,50 03 x SHIM D=10/2,55 03 x SHIM D=10/2,60 03 x SHIM D=10/2,65 03 x SHIM D=10/2,70 03 x SHIM D=10/2,75 03 x SHIM D=10/2,80 03 x SHIM D=10/2,85 03 x SHIM D=10/2,90 03 x SHIM D=10/2,95 03 x SHIM D=10/3,00 03 x SHIM D=10/3,05 03 x SHIM D=10/3,10 03 x SHIM D=10/3,15 03 x SHIM D=10/3,20 03 x VALVE COLLET LK 6H VALVE SPRING RETAINER VALVE SPRING NHK VALVE-STEM SEALING RACING VALVE SPRING HOLDER INTAKE VALVE D=42/6 (TI) EXHAUST VALVE D=34/6 (ST) / C * NEW PART X AS REQUIRED 17

20 TIMING DRIVE HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH SCR. PLUG TIM. CHAIN TENS. CPL O-RING 22,00X2,00 B CHAIN ADJUSTER HYD GUIDE RAIL TOP CAMSHAFT INTAKE CAMSHAFT EXHAUST CAMSHAFT IN/RE CPL CAMSHAFT EXHAUST GUIDE RAIL TENSIONER RAIL TIMING CHAIN IDLER GEAR L/S NEEDLE BEARING K 15X19X24ZW BEARING BOLT 15X57, STOP DISK 15,2X25X IDLER GEAR R/S COLLAR SCREW ANGLE PIECE F. BREATHER SYSTEM HH COLLAR SCREW M 6X20 WS= / C * NEW PART X AS REQUIRED 18

21 CYLINDER HEAD REAR AH SCREW DIN7984-M 8X AH SCREW DIN0912-M 6X VALVE COVER GASKET SET CYL.HEAD RC8 REAR CYLINDER HEAD GASGET TEMPERAT.-SENSOR WATER LC VACUUM CONECTION STUD M 8X OIL JET VALVE GUIDE EXHAUST VALVE GUIDE INTAKE NEEDLE ROLLER DIN5402 5X9, CONNECTING ANGLE O-RING 15,00X1,50 VITON O-RING 12,00X2,00 NBR VALVE COVER REAR COLLAR SCREW M 6 WS= INSERT SPARK-PLUG SHAFT O-RING 29,87X1,78 VITON WASHER 11,1X20X CYLINDER HEAD SCREW RUBBERSLEEVE INTAKE FLANGE HOSE CLAMP GEMI 66 / VACUUM CONECTION M6/0,5MM WASHER DIN0125-A 6, HH CAP NUT DIN1587-M 6 SS O-RING 10,00X2,00 SILCONE WATER CONNECTION CPL HH COLLAR SCREW M 6X20 WS= SCREW PLUG O-RING 9X1,5 NBR EXHAUST PIPE FLANGE GASKET COLLAR SCREW M6/M AH.SCREW DIN0912-M 4X CONNECTING ANGLE RETAIN. PLATE GASKET SET CYLINDER+HEAD F+R / C * NEW PART X AS REQUIRED 19

22 CYLINDER HEAD FRONT AH SCREW DIN0912-M 6X VALVE COVER GASKET SET VALVE COVER FRONT COLLAR SCREW M 6 WS= INSERT SPARK-PLUG SHAFT O-RING 29,87X1,78 VITON CYLINDER HEAD SCREW WASHER 11,1X20X RUBBERSLEEVE INTAKE FLANGE HOSE CLAMP GEMI 66 / OIL JET OIL-PRESSURE SWITCH LC VACUUM CONECTION M6/0,5MM CYLINDER HEAD GASGET STUD M 8X CYL.HEAD RC8 FRONT NEEDLE ROLLER DIN5402 5X9, AH SCREW DIN7984-M 8X VALVE GUIDE EXHAUST VALVE GUIDE INTAKE VACUUM CONECTION TEMPERAT.-SENSOR WATER LC WASHER DIN0125-A 6, HH CAP NUT DIN1587-M 6 SS O-RING 10,00X2,00 SILCONE O-RING 9X1,5 NBR WATER CONNECTION CPL HH COLLAR SCREW M 6X20 WS= EXHAUST PIPE FLANGE GASKET SCREW PLUG GASKET SET CYLINDER+HEAD F+R / C * NEW PART X AS REQUIRED 20

23 LUBRICATING SYSTEM HH COLLAR SCREW M 6X15 WS= HH COLLAR SCREW M 6X20 WS= O-RING 30X2,0 FPM O-RING 32,00X2, OIL FILLER PLUG CPL OIL JET 70 M OIL SCREEN BUSHING OIL SCREEN CPL OIL FILTER O-RING 14,00X2, O-RING 12,5X1,5 NBR O-RING 17,00X2, OIL INJECTION TUBE CPL O-RING 10,00X1,00 NBR 70 SH HH COLLAR SCREW M 6X25 WS= TAB WASHER DIN6799 RS WASHER 10X16X0, OIL PUMP GEAR 24-T NEEDLE ROLLER NRB 4X15,8 G PRESSURE PUMP COVER CONTROL PISTON LC CIRCLIP DIN0472 J WASHER 6X12X1 HRC CONTROL SPRING ROTOR-SET 19MM OIL PUMP SHAFT ROTOR-SET 22MM ROTOR-SET 30MM MOLDED RING SUCTION PUMP COVER SUC. PUMP COVER CRANK CASE HH COLLAR SCREW M 6X20 WS= NEEDLE ROLLER DIN5402 5X9, MOLDED RING OIL COOLER CPL HH COLLAR SCREW M 6X50 WS= BUSHING / C * NEW PART X AS REQUIRED 21

24 LUBRICATING SYSTEM O-RING 12X2 VITON GREEN REGULATING SCREW O-RING 6,00X2,00 NBR / C * NEW PART X AS REQUIRED 22

25 IGNITION SYSTEM STICK COIL SPARK PLUG M12X1,25 NGK R CABLE SUPPORT GENERATOR HH COLLAR SCREW M 5X16 WS= PULSER COIL KOKUSAN 4K3-A/B FLYWHEEL CPL HH COLLAR SCREW M 6X25 WS= IGNITION COVER GASKET DOWEL 9,8 X 7 X STATOR IGNITION COVER WITH BEARING O-RING 24X2,5 NBR SCREW PLUG M24X1,5 PA WASHER 12,5/25/ SCREW M12X1, OIL JET "60" M HH COLLAR SCREW M 6X30 SW= / C * NEW PART X AS REQUIRED 23

26 ELECTRIC STARTER SELF LOCK. NUT DIN0985-M WASHER DIN0125-A 6, E-STARTER ENGINE 9T NEEDLE SLEEVE HK /14/ WASHER 10X16X0, GROOV.BALL BEAR RSR C TORQUE LIMITER 10/45 CPL BEARING BOLT 15X NEEDLE BEARING K 15X19X INTERMEDIATE GEAR 43T STOP DISK 15,2X25X NEEDLE BUSH HK /42/ FLYWHEEL CPL AH SCREW DIN6912-M 6X FREEWHEEL GEAR CPL. 66T HH COLLAR SCREW M 6X25 WS= FREEWHEEL HOLDER SUPPORTING SLEEVE HH COLLAR SCREW M 6X30 SW= O-RING 33,5X3 VITON / C * NEW PART X AS REQUIRED 24

27 THROTTLE BODY SCREW FOR PLASTIC D=5X AMBIENT-AIR TEMPERATURE SENSOR RUBBER SUPP. PRESSURE SENS PRESSURE SENSOR VACUUM CONECTION HOSE 3,2X8,5 PER METER x INTAKE TRUMPET THROTTLE BODY CPL. DK SENSOR-RETAIN. PLATE AIRBOX HOLDER WIRING HARNESS REAR EJOT PT SCREW K50X TIMING CHARGER EFI VIBRATION DAMPER DIGITALBOX WASHER DIN9021-A 5, AH SCREW DIN 912-M 4X SHIM 4,3X15X1,25MM GALVANIZED ROLLOVER SENSOR HH COLLAR SCREW M6X10 TX HOLDER ROLLOVER SENSOR O-RING SEAL RING INJECTOR CPL FUEL HOSE CPL SCREW SHOULDER SCREW FOR SUPPORT STEPPER MOT / C * NEW PART X AS REQUIRED 25

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32 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM089851HEN* 3CM089851HEN Art.Nr.: 3CM089851HEN 7/2008