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)