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.