KTM RC 125 2018 Manual

SETUP INSTRUCTIONS 2018
RC 125
Art. no. 3213840en

INTRODUCTION
*3213840en*
3213840en
01/2018
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete
technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice
and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular
model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
© 2018 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
RC 125 EU (F5003R1, F5003R2)

1 MEANS OF REPRESENTATION
2
1.1 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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
A00034-10
–Remove the straps and box.
S01886-01
–Remove the adhesive tape in the upper area of the motorcycle.
A00043-10
–Roll down the film at the sides.
Info
To avoid damaging the motorcycle during unpacking,
leave the other films on the vehicle until you have fin-
ished work on the vehicle.
–Remove the separate enclosure and unpack it. Check the sepa-
rate enclosure for completeness.
–Check the vehicle for transport damage.
S01885-10
Condition
Left and right handlebar stub not mounted.
–Remove protective film on the left and right handlebar
stub.
–Mount left and right handlebar stub on the upper triple
clamp.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Mount and tighten screws 1.
Guideline
Screw, handle-
bar stub
M6 8 Nm (5.9 lbf ft)
Loctite®243™
–Mount and tighten screws 2.
Guideline
Screw, anti-rotation
lock, handlebar
stub
M5 4 Nm (3 lbf ft)

2 SETUP
4
–Check the clutch lever play. ( p. 6)
–Check the play in the throttle cable. ( p. 7)
S01888-10
–Position damping rubber 3on both sides.
–Join plug-in connector 4of the mirror on both sides.
–Position the rear mirror on both sides. Mount and tighten the
screws.
–Position all controls in their exact positions on the handlebar.
–Tighten all screws.
F01048-10
–Mount reflector 5with spring washers 6on holding
plate 7.
–Mount the retaining plate on the license plate holder.
–Mount the license plate holder.
–Carefully loosen and remove the tension belt over the
swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tension belts around the lower
triple clamp.
The vehicle is released at the front.
–Take the vehicle off the palette together with an assistant.
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 safety
glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and
consult a doctor immediately if battery acid and
battery gases get into the eyes.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 10)
–Remove the front rider's seat. ( p. 8)
–Store the tool set below the seat.
–Remove the battery cover. ( p. 9)

SETUP 2
5
S01889-01
–Remove spare key and KEYCODECARD and keep in a safe place
for the handover.
–Install the battery. ( p. 11)
–Remove the remaining films.
–Refuel. ( p. 14)
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

3 WORK
6
3.1 Checking the clutch lever play
Note
Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.
–Check the free travel of the clutch lever each time before using the motorcycle.
–Adjust the free travel of the clutch lever when necessary in accordance with the specification.
V00625-11
–Check the clutch lever for smooth operation.
–Move the handlebar to the straight-ahead position.
–Pull the clutch lever until resistance is perceptible, and deter-
mine the play in the clutch lever A.
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
» If the clutch lever play does not meet the specified value:
–Adjust play in the clutch lever. ( p. 6)
–Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
» If the clutch lever play changes:
–Check the routing of the clutch cable.
3.2 Adjusting play in the clutch lever
V00672-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the play in the clutch level Aby turning adjusting
screw 3.
Guideline
Clutch lever play A1 … 3 mm (0.04 …
0.12 in)
–Tighten lock nut 2.
–Position bellows 1.

WORK 3
7
3.3 Checking the play in the throttle cable
400192-11
–Check the throttle grip for smooth operation.
–Move the handlebar to the straight-ahead position. Turn the
throttle grip back and forth slightly and determine the play in
throttle cable A.
Throttle cable play A3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
–Adjust the play in the throttle cable. ( p. 7)
Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
–Always make sure there is sufficient ventilation
when running the engine.
–Use an effective exhaust extraction system when
starting or running the engine in an enclosed
space.
–Start the engine and let it run idle. Move the handlebar to and
fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
–Check throttle cable routing.
3.4 Adjusting the play in the throttle cable
V00671-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the play in the throttle cable by turning adjusting
screw 3.
Guideline
Throttle cable play 3 … 5 mm (0.12 … 0.2 in)
–Tighten lock nut 2.
–Slide on sleeve 1.
3.5 Removing the passenger seat
Preparatory work
–Remove the front rider's seat. ( p. 8)

3 WORK
8
V00639-10
Main work
–Remove screw 1with washer.
–Lift and take off the passenger seat.
3.6 Mounting the passenger seat
V00640-10
Main work
–Position passenger seat.
Both hooks 1engage in the holders 2.
–Lower the front of the passenger seat and push back.
V00639-11
–Mount and tighten screw 3with the washer.
Guideline
Screw, passenger
seat
M6 7 Nm (5.2 lbf ft)
Warning
Danger of accidents The seat can come loose from the
anchoring if it is not mounted correctly.
–After assembly, check whether the seat is correctly
locked and cannot be pulled up.
–Check that the passenger seat is mounted correctly.
Finishing work
–Mount the front rider's seat. ( p. 9)
3.7 Removing the front rider's seat
V00633-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the front rider's seat, pull it toward the rear,
and remove it upward.
–Remove the ignition key from the seat lock.

WORK 3
9
3.8 Mounting the front rider's seat
H01084-10
–Attach recesses 1on the front rider's seat to the fuel tank,
push the front rider's seat forward, and lower at the rear.
The pin 2locks audibly in place.
–Check that the front rider's seat is mounted correctly.
3.9 Removing the battery cover
Preparatory work
–Remove the front rider's seat. ( p. 8)
V00642-10
Main work
–Pull loop 1toward the rear.
–Pull battery cover 2forward and take off toward the top.
3.10 Mounting the battery cover
V00643-10
Main work
–Position battery cover 1and pull toward the rear.
The battery cover engages with an audible click.
–Check the battery cover is seated correctly.
Finishing work
–Mount the front rider's seat. ( p. 9)

3 WORK
10
3.11 Recharging 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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Note
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Remove the front rider's seat. ( p. 8)
–Remove the battery cover. ( p. 9)
–Disconnect the negative cable of the battery. ( p. 11)
311910-10
Main work
–Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)
Alternative 1
US battery charger XCharge-professional
(00029095051)
Alternative 2
UK battery charger XCharge-professional
(00029095052)

WORK 3
11
Alternative 3
CH battery charger XCharge-professional
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly
when the motorcycle is not
in use
3 months
Finishing work
–Mount the front rider's seat. ( p. 9)
–Set the clock. ( p. 12)
3.12 Disconnecting the negative cable of the battery
Preparatory work
–Remove the front rider's seat. ( p. 8)
–Remove the battery cover. ( p. 9)
V00663-10
Main work
–Disconnect negative cable 1of the battery.
3.13 Installing the battery
V00664-11
Main work
–Mount rubber band 1on the battery compartment.
–Position the battery in the battery holder.
Guideline
The terminals of the battery must face upwards.
Battery (ETZ-9-BS)
–Reconnect rubber band 1.
–Position positive cable 2and mount and tighten the screw.
–Position positive terminal cover 3.

3 WORK
12
V00663-11
–Position negative cable 4; mount and tighten the screw.
Finishing work
–Mount the battery cover. ( p. 9)
–Mount the front rider's seat. ( p. 9)
–Set the clock. ( p. 12)
3.14 Setting the clock
Info
The clock is displayed in 24-hour format.
The time must be reset if the battery was disconnected from the vehicle or the fuse was removed.
Condition
The motorcycle is stationary.
F01455-10
–Press the MODE button briefly and repeatedly until ODO appears
on the display.
–Press the MODE button and SET button simultaneously for 5
seconds.
The time display begins to flash.
Info
The clock can be set in the ODO display for each menu
by keeping the MODE button and SET button pressed
simultaneously.
–Set the hours display using the MODE button.
–Set the minutes display using the SET button.
–Press the MODE button and SET button simultaneously.
The set time is adopted and saved.
3.15 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.

WORK 3
13
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
V00630-10
–Lift the cover 1of the filler cap and insert the ignition key in
the lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the filler cap to take pressure off the igni-
tion key.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
–Remove the ignition key.
3.16 Closing the filler cap
V00631-01
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check the filler cap is locked correctly after clos-
ing.
–Change your clothing in case of fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Close the filler cap.
–Push down the filler cap until the lock engages.

3 WORK
14
3.17 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
V00632-10
–Switch off the engine.
–Open the filler cap. ( p. 12)
–Fill the fuel tank with fuel up to the lower edge 1of the fuel
filler.
Total fuel tank
capacity, approx.
10 l
(2.6 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 18)
–Close the filler cap. ( p. 13)

TECHNICAL DATA 4
15
4.1 Chassis tightening torques
Screw, chain guard EJOT PT®K60x30 4 Nm (3 lbf ft)
Remaining screws, chassis M4 4 Nm (3 lbf ft)
Screw, engine electronics control
unit
M4 3 Nm (2.2 lbf ft)
Nut, chain guard M5 7 Nm (5.2 lbf ft)
Nut, reflector on retaining plate M5 5 Nm (3.7 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, anti-rotation lock, handle-
bar stub
M5 4 Nm (3 lbf ft)
Screw, battery compartment M5 4 Nm (3 lbf ft)
Screw, cover in front of battery
compartment
M5 4 Nm (3 lbf ft)
Screw, fuel tank cover M5 4 Nm (3 lbf ft)
Screw, retaining plate on license
plate holder
M5 4 Nm (3 lbf ft)
Screw, side stand switch M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, tail end lower part M5 4 Nm (3 lbf ft)
ABS fitting M6 7 Nm (5.2 lbf ft)
Loctite®243™
Battery compartment cover lock M6 6 Nm (4.4 lbf ft)
Nut, license plate holder M6 7 Nm (5.2 lbf ft)
Nut, radiator M6 5 Nm (3.7 lbf ft)
Nut, tail light M6 7 Nm (5.2 lbf ft)
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft)
Remaining screws, chassis M6 9 Nm (6.6 lbf ft)
Screw, air filter box cover M6 6 Nm (4.4 lbf ft)
Screw, air filter box, on frame M6 6 Nm (4.4 lbf ft)
Screw, battery compartment M6 6 Nm (4.4 lbf ft)
Screw, brake fluid reservoir, rear
brake
M6 8 Nm (5.9 lbf ft)
Screw, brake hose clamp M6 6 Nm (4.4 lbf ft)
Screw, brake line guide on bottom
triple clamp
M6 7 Nm (5.2 lbf ft)
Loctite®243™
Screw, chain guard M6 6 Nm (4.4 lbf ft)
Screw, chain sliding guard M6 7 Nm (5.2 lbf ft)
Screw, compensating tank M6 8 Nm (5.9 lbf ft)
Screw, engine electronics control
unit retaining bracket
M6 6 Nm (4.4 lbf ft)
Screw, engine sprocket cover on
frame
M6 8 Nm (5.9 lbf ft)
Screw, footrest bracket M6 7 Nm (5.2 lbf ft)
Screw, front fairing structure on
headlight bracket
M6 7 Nm (5.2 lbf ft)
Screw, front fender on axle clamp M6 7 Nm (5.2 lbf ft)

4 TECHNICAL DATA
16
Screw, front mask M6 7 Nm (5.2 lbf ft)
Screw, front seat fixing M6 6 Nm (4.4 lbf ft)
Screw, front spoiler M6 7 Nm (5.2 lbf ft)
Screw, front spoiler bottom front M6 6 Nm (4.4 lbf ft)
Screw, front spoiler rear M6 6 Nm (4.4 lbf ft)
Screw, fuel tank trim M6 6 Nm (4.4 lbf ft)
Screw, ground cable, on frame M6 7 Nm (5.2 lbf ft)
Screw, handlebar stub M6 8 Nm (5.9 lbf ft)
Loctite®243™
Screw, license plate holder on
license plate bracket
M6 7 Nm (5.2 lbf ft)
Screw, magnetic holder on side
stand
M6 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, passenger seat M6 7 Nm (5.2 lbf ft)
Screw, protective plate M6 8 Nm (5.9 lbf ft)
Screw, radiator shield M6 6 Nm (4.4 lbf ft)
Screw, rear ABS sensor wheel M6 8 Nm (5.9 lbf ft)
Loctite®204™
Screw, rear fender M6 7 Nm (5.2 lbf ft)
Screw, rollover sensor M6 7 Nm (5.2 lbf ft)
Loctite®243™
Screw, rubber damper for radiator M6 6 Nm (4.4 lbf ft)
Screw, side cover M6 6 Nm (4.4 lbf ft)
Screw, side cover on front mask M6 6 Nm (4.4 lbf ft)
Screw, side cover retaining bracket M6 7 Nm (5.2 lbf ft)
Screw, wheel speed sensor holder M6 8 Nm (5.9 lbf ft)
Screw, windshield M6 7 Nm (5.2 lbf ft)
Exhaust clamp M8 20 Nm (14.8 lbf ft)
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, chain guard M8 11 Nm (8.1 lbf ft)
Screw, foot brake lever M8 17 Nm (12.5 lbf ft)
Loctite®243™
Screw, front brake disc M8 32 Nm (23.6 lbf ft)
Loctite®243™
Screw, front wheel spindle M8 26 Nm (19.2 lbf ft)
Screw, fuel tank attachment, rear,
on frame
M8 17 Nm (12.5 lbf ft)
Screw, horn M8 9 Nm (6.6 lbf ft)
Screw, main silencer M8 18 Nm (13.3 lbf ft)
Screw, passenger foot pegs bracket M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, presilencer on frame M8 24 Nm (17.7 lbf ft)
Screw, rear brake disc M8 21 Nm (15.5 lbf ft)
Loctite®243™
Screw, retaining bracket on fuel
tank
M8 13 Nm (9.6 lbf ft)

TECHNICAL DATA 4
17
Screw, shift lever M8 17 Nm (12.5 lbf ft)
Loctite®243™
Screw, top triple clamp M8 15 Nm (11.1 lbf ft)
Screw, front brake caliper M8x1 30 Nm (22.1 lbf ft)
Loctite®204™
Nut, rear sprocket screw M8x1.25 27 Nm (19.9 lbf ft)
Loctite®243™
Fitting side stand M10 35 Nm (25.8 lbf ft)
Loctite®243™
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, side stand pivot M10 35 Nm (25.8 lbf ft)
Screw, front footrest bracket /
engine bearer
M10x1.25 49 Nm (36.1 lbf ft)
Nut, rear wheel spindle M14x1.5 90 Nm (66.4 lbf ft)
Nut, swingarm pivot M14x1.5 100 Nm (73.8 lbf ft)
Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft)
Loctite®204™
Lambda sensor M18x1.5 19 Nm (14 lbf ft)
Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no
play
Nut, steering head M30x1 1.
55 Nm (40.6 lbf ft)
2. Loosen (counterclockwise)
2 turns
3.
5 Nm (3.7 lbf ft)

5 SUBSTANCES
18
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).