KTM RC 125 Manual

SETUP INSTRUCTIONS 2020
RC 125
Art. no. 3214236en

INTRODUCTION
*3214236en*
3214236en
01/2020
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 contained herein 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 produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures 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.
© 2020 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)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
RC 125 EU (F5003T1, F5003T2)

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 Transport mode
H02713-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Diagnostics connector
H01911-10
Diagnostics connector 1is located under the front rider's seat.
2.3 Unpacking and setting up the vehicle
A00034-10
–Remove the straps and the box.
S01886-01
–Remove the adhesive tape in the upper area of the motorcycle.

2 SETUP
4
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.
Info
The procedure in the event of missing components is
described in the customer service manual.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the customer service manual.
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)
–Position the clutch and hand brake assembly on the han-
dlebar stubs, mount the clamp screws and tighten.
–Attach the clutch cable to the clutch lever and slide on the
protection cap.
–Connect the cable of the brake light switch to the hand
brake assembly.

SETUP 2
5
S01888-10
–Position damping rubber 3on both sides.
–Join plug-in connector 4of the rear 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.
–Check the throttle cable play. ( p. 8)
H03807-10
–Make sure that the clutch cable is attached to the clutch
release lever and secured.
–Check the clutch lever play. ( p. 7)
F01048-10
–Mount rear 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 link fork.
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.
–Together with an assistant, take the vehicle off the pallet.
Warning
Risk of injury Battery acid and battery gases cause
serious chemical burns.
–Keep 12 V 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 12 V
battery.
–Only charge 12 V 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 12 V battery.

2 SETUP
6
Info
Read the notes in the 12 V battery accessory pack.
–Charge the 12-V battery. ( p. 11)
–Remove the front rider's seat. ( p. 9)
–Store the tool set below the seat.
–Remove the battery cover. ( p. 10)
S01889-01
–Remove spare key and KEYCODECARD and keep in a safe place
for the handover.
–Install the 12-V battery. ( p. 13)
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Refuel. ( p. 15)
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.

WORK 3
7
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. 7)
–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.

3 WORK
8
3.3 Checking throttle cable play
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 specifications:
–Adjust the throttle cable play. ( p. 8)
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 effective exhaust extraction when starting or
running the engine in an enclosed space.
–Start the engine and let it run at idle speed. Move the handle-
bar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
–Check the throttle cable routing.
3.4 Adjusting throttle cable play
V00671-10
–Move the handlebar to the straight-ahead position.
–Push back sleeve 1.
–Loosen lock nut 2.
–Adjust the throttle cable play with barrel adjuster 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. 9)

WORK 3
9
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. 10)
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.

3 WORK
10
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. 9)
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. 10)

WORK 3
11
3.11 Charging the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep 12 V 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 12 V battery.
–Only charge 12 V 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 12 V batteries contain environmentally hazardous materials.
–Do not dispose of 12 V batteries as household waste.
–Dispose of 12 V 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 if there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the
safety valves. This reduces the capacity of the 12-V battery.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and sulfating occurs, destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the front rider's seat. ( p. 9)
–Remove the battery cover. ( p. 10)
–Disconnect the negative cable of the 12-V battery. ( p. 12)
311910-10
Main work
–Connect the battery charger to the 12-V 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)

3 WORK
12
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 12-V battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery
regularly when the motorcy-
cle is not being used
3 months
Finishing work
–Connect the negative cable of the 12-V battery. ( p. 12)
–Mount the battery cover. ( p. 10)
–Mount the front rider's seat. ( p. 10)
–Set the clock. ( p. 13)
3.12 Disconnecting the negative cable of the 12-V battery
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the front rider's seat. ( p. 9)
–Remove the battery cover. ( p. 10)
V00663-10
Main work
–Disconnect negative cable 1of the 12-V battery.
3.13 Connecting the negative cable of the 12-V battery
V00663-10
Main work
–Connect negative cable 1of the 12-V battery.
Finishing work
–Mount the battery cover. ( p. 10)
–Mount the front rider's seat. ( p. 10)

WORK 3
13
–Set the clock. ( p. 13)
3.14 Installing the 12-V battery
V00664-11
Main work
–Mount rubber strap 1on the battery compartment.
–Position the 12-V battery in the battery compartment.
Guideline
The terminals of the battery must face upwards.
12-V battery (ETZ-9-BS)
–Attach rubber strap 1.
–Position positive cable 2and mount and tighten the screw.
–Position positive terminal cover 3.
V00663-11
–Position negative cable 4; mount and tighten the screw.
Finishing work
–Mount the battery cover. ( p. 10)
–Mount the front rider's seat. ( p. 10)
–Set the clock. ( p. 13)
3.15 Setting the clock
Info
The time is displayed in 24-hour format.
The time must be reset if the 12-V 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.

3 WORK
14
–Press the MODE button and SET button simultaneously.
The set time is adopted and saved.
3.16 Opening fuel tank 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.
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 cover 1of the fuel tank filler cap and insert the ignition
key into the lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the fuel tank filler cap to take pressure off
the ignition key.
–Turn the ignition key 90° clockwise.
–Lift the fuel tank filler cap.
–Remove the ignition key.

WORK 3
15
3.17 Closing the fuel tank filler cap
V00631-01
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check that the fuel tank filler cap is locked cor-
rectly after closing.
–Change your clothing if fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Close the fuel tank filler cap.
–Push down the fuel tank filler cap until the lock engages.
3.18 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.

3 WORK
16
S03383-10
–Switch off the engine.
–Open the fuel tank filler cap. ( p. 14)
–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. 20)
–Close the fuel tank filler cap. ( p. 15)

TECHNICAL DATA 4
17
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 sensor 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, damping rubber for radiator M6 6 Nm (4.4 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)

4 TECHNICAL DATA
18
Screw, front fender on axle clamp M6 7 Nm (5.2 lbf ft)
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 fender M6 7 Nm (5.2 lbf ft)
Screw, rear wheel speed sensor
wheel
M6 8 Nm (5.9 lbf ft)
Loctite®204™
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, tilt sensor M6 7 Nm (5.2 lbf ft)
Loctite®243™
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 footrest unit 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)