KTM RC 125 Owner's Manual
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KTM RC 125 Owner's Manual

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OWNER'S MANUAL
2016
RC 125
RC 200
Art. no. 3213406en

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Summary of Contents for KTM RC 125

  • Page 1 OWNER'S MANUAL 2016 RC 125 RC 200 Art. no. 3213406en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 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 assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS CONTROLS..............22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Clutch lever............22 Symbols used ............7 Hand brake lever..........22 Formats used............8 Throttle grip ............23 SAFETY ADVICE.............. 9 Horn button............23 Use definition............9 Light switch ............
  • Page 6 TABLE OF CONTENTS Filling level display in fuel tank ......42 Stopping, parking..........68 TRIP F display ........... 43 Transport ............69 Coolant temperature indicator ......44 Refueling ............70 7.10 Info display ............45 10 SERVICE SCHEDULE ............ 72 7.11 Riding time/average speed menu ......
  • Page 7 15.3 Recharging the battery ........133 12.18 Fitting front spoiler ..........98 15.4 Changing the ABS fuses (RC 125) ..... 136 12.19 Removing the left side cover ......100 15.5 Changing the fuses of individual power 12.20 Installing the left side cover ......
  • Page 8 Preparing for use after storage......170 21 TROUBLESHOOTING ..........171 22 BLINK CODE .............. 174 23 TECHNICAL DATA............180 23.1 Engine ............180 23.1.1 RC 125 ............180 23.1.2 RC 200 ............181 23.2 Engine tightening torques ......... 183 23.3 Capacities ............185 23.3.1...

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 10: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 11: Safety Advice

    SAFETY ADVICE Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.

  • Page 12: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 13: Safe Operation

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 14: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 15: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 16: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 17: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 18: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) L02145-10...
  • Page 19 VIEW OF VEHICLE Horn button ( p. 23) Light switch ( p. 24) High beam flasher button ( p. 24) Turn signal switch ( p. 25) Clutch lever ( p. 22) Filler cap Seat lock ( p. 29) Side stand ( p.

  • Page 20: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) L02146-10...
  • Page 21 VIEW OF VEHICLE Grab handles ( p. 30) Tool set ( p. 30) Ignition/steering lock ( p. 26) Emergency OFF switch ( p. 25) Electric starter button ( p. 26) Throttle grip ( p. 23) Hand brake lever ( p. 22) Passenger footrests ( p.

  • Page 22: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the right side of the frame under the seat. 402175-10 Type label  The type label is on the right of the frame behind the steering head. 0 0 1 402174-10...

  • Page 23: Engine Number

    SERIAL NUMBERS Engine number  The engine number is stamped on the left side of the engine under the engine sprocket. 402486-10 Key number  The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 24: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. L02111-10 Hand brake lever  The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. L02112-10...

  • Page 25: Throttle Grip

    CONTROLS Throttle grip  The throttle grip is fitted on the right side of the handlebar. L02112-11 Horn button  The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed –...

  • Page 26: Light Switch

    CONTROLS Light switch  The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – The light switch is turned upwards. In this position, the low beam, the high beam and the tail light are switched on.

  • Page 27: Turn Signal Switch

    CONTROLS Turn signal switch  The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on –...

  • Page 28: Electric Starter Button

    CONTROLS Electric starter button  The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button L02114-11 6.10 Ignition/steering lock...

  • Page 29: Locking The Steering

    CONTROLS 6.11 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar all the way to the left. –...

  • Page 30: Opening The Filler Cap

    CONTROLS 6.13 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 31: Closing The Filler Cap

    CONTROLS – Remove the ignition key. 6.14 Closing the filler cap Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.

  • Page 32: Tool Set

    CONTROLS 6.16 Tool set  The tool set is in the storage compartment under the seat. L02154-10 6.17 Grab handles  The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. L02119-10...

  • Page 33: Passenger Footrests

    CONTROLS 6.18 Passenger footrests The passenger footrests can be folded in and out. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • L02120-10 6.19 Shift lever ...

  • Page 34: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.20 Foot brake lever  Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 402177-10...

  • Page 35: Side Stand

    CONTROLS 6.21 Side stand  The side stand is on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states Side stand folded out –...

  • Page 36: Combination Instrument

    COMBINATION INSTRUMENT Overview Display ( p. 41) Function buttons ( p. 39) Info display ( p. 45) Indicator lamps ( p. 40) 401685-10...

  • Page 37: Activation And Test

    COMBINATION INSTRUMENT Activation and test Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up briefly.

  • Page 38: Warning Notes

    COMBINATION INSTRUMENT Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low. 401309-01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark. 401310-01...
  • Page 39 COMBINATION INSTRUMENT High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401311-01 Side Stand Down appears on the info display if the side stand is folded down. 401312-01 Low Battery appears on the info display if the battery voltage falls below the specified value.
  • Page 40 COMBINATION INSTRUMENT Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment. 401461-01...

  • Page 41: Function Buttons

    1 (TRIP 1) and  distance 2 (TRIP 2) functions to 0.0 and briefly pressing the SET button changes the info display to the next display mode. (RC 125)  The ABS can be switched off using button (RC 200) Button ...

  • Page 42: Indicator Lamps

    (optional). The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown in the info display. (RC 125) ABS warning lamp lights up/flashes yellow – Status or error messages 401686-01...

  • Page 43: Display

    COMBINATION INSTRUMENT Display  is shown in kilometers per hour km/h or in miles per hour mph. The speed  The tachometer shows the engine speed in revolutions per minute.  The gear display shows the engaged gear.  The coolant temperature appears in segment ...

  • Page 44: Filling Level Display In Fuel Tank

    COMBINATION INSTRUMENT Filling level display in fuel tank The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank. 401292-01...

  • Page 45: Trip F Display

    COMBINATION INSTRUMENT TRIP F display If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note Low Fuel Level appears on the info display.

  • Page 46: Coolant Temperature Indicator

    COMBINATION INSTRUMENT Coolant temperature indicator The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Coolant Temperature. Possible states Engine cold –...

  • Page 47: Info Display

    COMBINATION INSTRUMENT 7.10 Info display  Various warning notes appear on info display If the general warning lamp lights up, the corresponding warning note is shown on the info display. 401291-10...

  • Page 48: Riding Time/Average Speed Menu

    COMBINATION INSTRUMENT 7.11 Riding time/average speed menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed in this menu.

  • Page 49: Average Fuel Consumption 1/Average Fuel Consumption 2 Menu

    COMBINATION INSTRUMENT In this menu, the average speed and the average fuel consumption 1 are displayed in L/100 km (or L/100 miles). Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0.

  • Page 50: Average Fuel Consumption 2/Service Menu

    COMBINATION INSTRUMENT Press the SET button Next display mode on the info display briefly. 7.14 Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. •...

  • Page 51: Service/Range Menu

    COMBINATION INSTRUMENT 7.15 Service/range menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the range.

  • Page 52: Range/Riding Time Menu

    COMBINATION INSTRUMENT 7.16 Range/riding time menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu.

  • Page 53: Total Distance Menu Odo

    COMBINATION INSTRUMENT 7.17 Total distance menu ODO Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered.

  • Page 54: Distance Menu 1 Trip 1

    COMBINATION INSTRUMENT 7.18 Distance menu 1 TRIP 1 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until TRIP 1 appears on the display. TRIP 1shows the distance since the last reset, such as between two refueling stops.

  • Page 55: Setting Kilometers Or Miles

    COMBINATION INSTRUMENT Press the SET button Display of TRIP 2 is reset for 5 - 10 seconds. Press the MODE but- Next display mode on the display ton. 7.20 Setting kilometers or miles Info Make the country-specific setting. Condition The ignition is on. The motorcycle is stationary.

  • Page 56: Setting The Time

    COMBINATION INSTRUMENT 7.21 Setting the time Condition The ignition is on. The motorcycle is stationary. – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE and SET buttons for 5 - 10 seconds. The time display begins to flash.

  • Page 57: Adjusting The Shift Speed Rpm 2

    COMBINATION INSTRUMENT Info The MODE button increases the value. The SET button decreases the value. – Do not activate the two buttons for approx. 15 seconds. The display RPM 1 goes out and the set speed is stored. 7.23 Adjusting the shift speed RPM 2 Condition The ignition is on.

  • Page 58: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling characteristic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 59: Running In The Engine

    PREPARING FOR USE – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. – Before your first trip, read the entire operating instructions carefully.

  • Page 60: Loading The Vehicle

    PREPARING FOR USE Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 61 PREPARING FOR USE – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.)

  • Page 62: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 63: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 64 – Shift gear to neutral. The green idling speed indicator lamp N lights up. B00782-10 (RC 125) The ABS warning lamp lights up and goes back out after starting off. – Press the electric starter button Info Do not press the electric starter button until the combination instrument func- tion check is finished.

  • Page 65: Starting Off

    RIDING INSTRUCTIONS Switching off ABS (RC 125) KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – button for 3 – 5 seconds. Press the ...
  • Page 66 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 67 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 68: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 69 There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. (RC 125) Warning Danger of accidents Greater stopping distance due to ABS.

  • Page 70: Stopping, Parking

    RIDING INSTRUCTIONS – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over rev the engine. In this way, you have to brake far less and the brakes do not overheat. (RC 200) Warning Danger of accidents If you brake too hard, the wheels can lock.

  • Page 71: Transport

    RIDING INSTRUCTIONS – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. –...

  • Page 72: Refueling

    RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
  • Page 73 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 74: Service Schedule

    Every 15,000 km (9,300 mi) Every 7,500 km (4,650 mi) After 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● Check the functioning of the electrical equipment. ○...
  • Page 75 Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 76: Recommended Work

    SERVICE SCHEDULE 10.3 Recommended work Every four years Every year Every 7,500 km (4,650 mi) After 1,000 km (620 mi) ● Check the swingarm bearing. ● Check the wheel bearings. ○ ● ● ● Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. ○...

  • Page 77: Tuning The Chassis

    TUNING THE CHASSIS 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situation of the spring process on the shock absorber.

  • Page 78: Adjusting The Shift Lever

    TUNING THE CHASSIS 11.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. –   Loosen nut , holding the threaded rod Info  has a left-handed thread. –   Loosen nut , holding the threaded rod –...
  • Page 79 TUNING THE CHASSIS – Tighten nut  , holding the threaded rod  Guideline Nut, shift rod M6LH 10 Nm (7.4 lbf ft) – Check the shift lever to ensure it is functioning properly and can move freely.

  • Page 80: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the supports of the wheel stand. –...

  • Page 81: Raising The Motorcycle With The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. –  Remove the rear wheel stand and lean the vehicle on the side stand 402029-10 12.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 82: Taking The Motorcycle Off Of The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Move the handlebar to the straight-ahead position. Position the wheel stand. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. L02148-01 12.4 Taking the motorcycle off of the front wheel stand Note...

  • Page 83: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS – Mount protection cap  L02126-10 Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 78) 12.5 Cleaning the dust boots of the fork legs (RC 200) –  Push dust boot of both fork legs downwards.
  • Page 84 Universal oil spray ( p. 199) – Press the dust boots back into their normal position. – Remove excess oil. (RC 125) –  Push dust boot of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes.

  • Page 85: Removing The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 12.6 Removing the front rider's seat –  Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the front rider's seat, pull it toward the rear, and remove it upward. –...

  • Page 86: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS 12.8 Removing the passenger seat Preparatory work – Remove the front rider's seat. ( p. 83) Main work –  Remove screw with the washer. – Lift and take off the passenger seat. L02191-10 12.9 Mounting the passenger seat Main work –...

  • Page 87: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw  with the washer. Guideline Screw, passenger seat 7 Nm (5.2 lbf ft) Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly. –...

  • Page 88: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 12.11 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 89: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 198) – After drying, apply chain spray. Chain lube for road use ( p.
  • Page 90 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – In the area of chain sliding guard, press the chain upward toward the swingarm and  determine chain tension Info  The upper chain section must be taut.

  • Page 91: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12.13 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.
  • Page 92 SERVICE WORK ON THE CHASSIS Main work (RC 200) –  Loosen nut –  Loosen nuts – Adjust the chain tension by turning adjusting screws  on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) ...
  • Page 93 SERVICE WORK ON THE CHASSIS (RC 125) –  Loosen nut – Loosen nuts  –  Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) ...

  • Page 94: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 12.14 Checking the chain, rear sprocket, and engine sprocket – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 95 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. –  Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) –  Measure the distance of 20 chain links in the lower chain section. Info 0 0 A Chain wear is not always even, so you should repeat this measurement at differ-...

  • Page 96: Removing The Battery Cover

    SERVICE WORK ON THE CHASSIS – Push the chain up in the area behind the chain guide. – Check the chain sliding guard for wear. » If the chain sliding guard has lost material due to wear to the extent that, in ...
  • Page 97 SERVICE WORK ON THE CHASSIS Main work –  Pull loop toward the rear. – Pull battery cover  forward and remove toward the top. L02144-10...

  • Page 98: Mounting The Battery Cover

    SERVICE WORK ON THE CHASSIS 12.16 Mounting the battery cover Main work –  Position battery cover and pull toward the rear. The battery cover engages with an audible click. – Check the battery cover is seated correctly. L02141-10 Finishing work –...
  • Page 99 SERVICE WORK ON THE CHASSIS – Remove screw  G00976-12 –  Remove screws G00977-12 –  Remove screw –  Remove screw – Take off the front spoiler. G01721-13...

  • Page 100: Fitting Front Spoiler

    SERVICE WORK ON THE CHASSIS 12.18 Fitting front spoiler Main work – Position the front spoiler. –  Mount and tighten screw Guideline Screw, front spoiler retaining bracket, 9 Nm (6.6 lbf ft) rear, on engine –  Mount and tighten screw Guideline G01721-14 Screw, front spoiler retaining bracket,...
  • Page 101 SERVICE WORK ON THE CHASSIS – Mount and tighten screw  Guideline Screw, front spoiler, right, on footrest 7 Nm (5.2 lbf ft) bracket G00976-13 –  Mount and tighten screws Guideline Screw, front spoiler 7 Nm (5.2 lbf ft) G01029-11 Finishing work –...

  • Page 102: Removing The Left Side Cover

    SERVICE WORK ON THE CHASSIS 12.19 Removing the left side cover –  Remove screws –  Remove screws –  Pull off holding lug in area G00963-10 –  Remove expanding rivet G00964-10...

  • Page 103: Installing The Left Side Cover

    SERVICE WORK ON THE CHASSIS – Swing the side cover outward. –   Pull hose out of hose guide – Take off the side cover. L02200-10 12.20 Installing the left side cover –   Position hose in hose guide L02200-11...
  • Page 104 SERVICE WORK ON THE CHASSIS – Position the side cover. –  Mount and tighten screws Guideline Screw, side cover 7 Nm (5.2 lbf ft) –  Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler. –...

  • Page 105: Removing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 12.21 Removing the right side cover –  Remove screws –  Remove screws –  Pull off holding lug in area L02178-10 –  Remove expanding rivet – Take off the side cover. L02185-10...

  • Page 106: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 12.22 Installing the right side cover – Position the side cover. –  Mount and tighten screws Guideline Screw, side cover 7 Nm (5.2 lbf ft) –  Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler.

  • Page 107: Brake System

    – Only use spare parts on the brake system which have been approved and recom- mended by KTM. – Only use tires/wheels approved by KTM with the corresponding speed index. – Maintain the specified tire air pressure. – Service work and repairs must be performed professionally. (Your authorized KTM workshop will be glad to help.)

  • Page 108: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to ...

  • Page 109: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 110: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 111: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 112: Checking The Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 113: Adding Rear Brake Fluid

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
  • Page 114 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 115: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 13.8 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 116: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. –...

  • Page 117: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM – Disconnect spring  – Move the foot brake lever back and forth between the end stop and the contact to the  foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3…...
  • Page 118 BRAKE SYSTEM – Disconnect spring  –    Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The range of adjustment is limited. –...

  • Page 119: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 78) – Raise the motorcycle with the front wheel stand. ( p. 79) Main work (RC 200) –   Loosen screw and screws –...

  • Page 120: Installing The Front Wheel

    WHEELS, TIRES (RC 125) –  Remove screws and push the fender to the side. – Remove screw  and pull wheel speed sensor  out of the hole. –   Loosen screw and screws –  Unscrew screw about 6 turns and press your hand on the screw to push the ...
  • Page 121 WHEELS, TIRES Main work (RC 200) –  Remove spacers – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the front wheel bearing. – Clean and grease the shaft seal rings ...
  • Page 122 WHEELS, TIRES (RC 125) –  Remove spacers – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the front wheel bearing. –   Clean and grease the shaft seal rings and mating surfaces of the spacers.

  • Page 123: Removing The Rear Wheel

    WHEELS, TIRES – Tighten screws  Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Take the motorcycle off of the front wheel stand. ( p. 80) – Take the motorcycle off of the rear wheel stand. ( p.
  • Page 124 WHEELS, TIRES Main work (RC 200) –   Remove nut and the washer. Remove chain adjuster –  Holding the rear wheel, withdraw wheel spindle with the washer and chain  adjuster – Push the rear wheel forward as far as possible and take the chain off the rear sprocket.

  • Page 125: Installing The Rear Wheel

    WHEELS, TIRES (RC 125) –   Remove screw and pull wheel speed sensor out of the hole. – Remove nut  and the washer. Remove chain adjuster  –  Holding the rear wheel, withdraw wheel spindle with the washer and chain adjuster.
  • Page 126 WHEELS, TIRES Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work (RC 200) – Check the rear hub rubber dampers. p.
  • Page 127  marks Nut, rear wheel spindle M14x1.5 90 Nm (66.4 lbf ft) (RC 125) – Check the rear hub rubber dampers. p. 127) L02192-12 –  Remove spacers –...
  • Page 128 WHEELS, TIRES – Clean the thread of the wheel spindle and nut  – Clean the mating surfaces of the brake caliper support and swingarm. – Position the rear wheel. The brake linings are correctly positioned. – Push the rear wheel as far forward as possible and place the chain on the rear sprocket.

  • Page 129: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 14.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. Preparatory work –...

  • Page 130: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 131: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.
  • Page 132 WHEELS, TIRES – Remove the dust cap. – Check tire air pressure when the tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) 400695-01 Rear 2.2 bar (32 psi)

  • Page 133: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing 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 goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 134: Installing The Battery

    ELECTRICAL SYSTEM – Pull back the positive terminal cover  –  Disconnect positive cable from the battery. –  Detach rubber band – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.

  • Page 135: Recharging The Battery

    ELECTRICAL SYSTEM – Position the negative cable  and mount and tighten the screw. –  Position the negative terminal cover L02156-11 Finishing work – Mount the battery cover. ( p. 96) – Mount the front rider's seat. ( p. 83) –...
  • Page 136 – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Info Even when there is no load on the battery, it still loses power steadily.
  • Page 137 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...

  • Page 138: Changing The Abs Fuses (Rc 125)

    ELECTRICAL SYSTEM 15.4 Changing the ABS fuses (RC 125) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info Two fuses for the ABS are located under the protective cap next to the negative terminal of the battery. These fuses protect the return pump and the hydraulic unit of the ABS.
  • Page 139 ELECTRICAL SYSTEM Fuse (75011088015) ( p. 188)  Replace spare fuse in the fuse box so that it is available if needed. – Mount the protection cap. To change the fuse of the ABS return pump: –  Take off the protection cap and remove fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.

  • Page 140: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box with the main fuse and fuses of the individual power consumers is located next to the positive terminal of the battery. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 141 ELECTRICAL SYSTEM Info  A defective fuse is indicated by a burned-out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses.
  • Page 142 ELECTRICAL SYSTEM (RC 125) – Open fuse box cover. – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 15 A - start auxiliary relay, alarm system (OPTIONAL) Fuse 3 - 15 A - control unit, power relay...

  • Page 143: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM Fuse (75011088010) ( p. 187) Fuse (75011088015) ( p. 188) Fuse (75011088030) ( p. 188) Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. –...
  • Page 144 ELECTRICAL SYSTEM Main work –  Turn socket counterclockwise. – Pull the socket with low beam bulb  out of the headlight housing. –  Disconnect the socket with the low beam bulb from connector and remove. – Connect the new socket with the low beam bulb to the connector. Low beam (H11 / Sockel PGJ19-2) ( p.

  • Page 145: Changing The High Beam Bulb

    ELECTRICAL SYSTEM 15.7 Changing the high beam bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 146: Checking The Low Beam Headlight Adjustment

    ELECTRICAL SYSTEM – Position the socket with the high beam bulb in the headlight housing. – Turn the socket clockwise. – Check that the lighting is functioning properly. L02165-10 15.8 Checking the low beam headlight adjustment – Position the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight.

  • Page 147: Checking The High Beam Headlight Adjustment

    ELECTRICAL SYSTEM » If the light-dark border does not meet specifications: – Adjust the headlight range of the low beam. ( p. 146) 15.9 Checking the high beam headlight adjustment – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.

  • Page 148: Adjusting The Headlight Range Of The Low Beam

    ELECTRICAL SYSTEM 15.10 Adjusting the headlight range of the low beam Main work –  Adjust the beam range of the low beam by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the low beam headlight setting).

  • Page 149: Cooling System

    COOLING SYSTEM 16.1 Cooling system  Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in   radiator cap . Heat expansion causes excess coolant to flow into compensating tank When the temperature falls, this surplus coolant is sucked back into the cooling system.

  • Page 150: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM The coolant is cooled by the air stream and a radiator fan  , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 402242-10 16.2 Checking the coolant level in the compensating tank...
  • Page 151 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

  • Page 152: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM 16.3 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
  • Page 153 COOLING SYSTEM » If the coolant level does not meet specifications: – Correct the coolant level. Coolant ( p. 195) – Mount the cap of the compensating tank. –  Remove radiator cap – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) »...

  • Page 154: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM 16.4 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 155: Draining The Coolant

    COOLING SYSTEM 16.5 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 156: Filling/Bleeding The Cooling System

    COOLING SYSTEM Guideline Plug, water pump drain hole (RC 125) 8 Nm (5.9 lbf ft) Plug, water pump drain hole (RC 200) 8 Nm (5.9 lbf ft) 16.6 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard.
  • Page 157 COOLING SYSTEM – Release bleeder screw  by three turns. – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately. Coolant ( p.
  • Page 158 COOLING SYSTEM – Install the right side cover. p. 104)

  • Page 159: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth  to ascertain play in the throttle cable. Throttle cable play 3…...

  • Page 160: Adjusting The Play In The Throttle Cable

    TUNING THE ENGINE 17.2 Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. –  Push back sleeve –  Loosen lock nut –  Adjust the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3…...

  • Page 161: Adjusting The Clutch Cable Play

    TUNING THE ENGINE » If the clutch lever play changes: – Check the routing of the clutch cable. 17.4 Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. –  Push back sleeve – Loosen lock nut ...

  • Page 162: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. ...
  • Page 163 –   Position oil screen and mount and tighten oil drain plug with the O-ring. Guideline L02168-10 Oil drain plug (RC 125) M24x1.5 15 Nm (11.1 lbf ft) Oil drain plug (RC 200) M24x1.5 15 Nm (11.1 lbf ft)
  • Page 164 Lubricate the O-ring of the oil filter cover. Mount oil filter cover – Mount and tighten the screws. Guideline Screw, oil filter cover (RC 125) 8 Nm (5.9 lbf ft) Screw, oil filter cover (RC 125) 12 Nm (8.9 lbf ft) Screw, oil filter cover (RC 200) 8 Nm (5.9 lbf ft)

  • Page 165: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove filler plug  and the O-ring from the clutch cover and fill up with engine oil. 0 0 6 Engine oil 1.5 l (1.6 qt.) Outside temper- Engine oil ature: 0… 50 °C (SAE 15W/50) (32…...
  • Page 166 SERVICE WORK ON THE ENGINE Main work –  Remove the oil filler plug with the O-ring from the clutch cover and fill up with 0 0 1 engine oil. Engine oil (SAE 15W/50) ( p. 195) Engine oil (SAE 10W/40) ( p.

  • Page 167: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 168 CLEANING, CARE Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.

  • Page 169: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Perfect Finish and high gloss polish for paints ( p. 199) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p.
  • Page 170 CLEANING, CARE – Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor. Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. –...

  • Page 171: Storage

    0… 35 °C (32… 95 °F) direct sunlight – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 78)

  • Page 172: Preparing For Use After Storage

    STORAGE – Raise the motorcycle with the front wheel stand. ( p. 79) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 173: Troubleshooting

    Operating error Go through the steps of starting the engine. p. 61) – Fault in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power Air filter is very dirty Change the air filter.
  • Page 174 Defect in radiator fan system Check the radiator fan system. – The engine diagnosis warning Fault in fuel injection system Read out the fault memory using the KTM diag- lamp (MIL) lights up red nostics tool. – Engine dies during the trip Lack of fuel Refuel.
  • Page 175 Check the charging voltage. nator – Check the open-circuit current. – The combination instrument shows Fuse 7 is blown (RC 125) Change the fuses of individual power consumers. nothing on the display p. 138) – Set the clock. ( p. 54) –...

  • Page 176: Blink Code

    BLINK CODE Blink code engine diagnostic warning lamp (MIL) 02 Engine diagnostic warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - measurement range or power problem Blink code engine diagnostic warning lamp (MIL) 06 Engine diagnostic warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high...
  • Page 177 BLINK CODE Blink code engine diagnostic warning lamp (MIL) 13 Engine diagnostic warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high Blink code engine diagnostic warning lamp (MIL) 14 Engine diagnostic warning lamp (MIL) flashes 1x long, 4x short...
  • Page 178 BLINK CODE Blink code engine diagnostic warning lamp (MIL) 17 Engine diagnostic warning lamp (MIL) flashes 1x long, 7x short Error level condition Lambda sensor - circuit fault Lambda sensor - input signal too low Lambda sensor - input signal too high Lambda sensor - no function Blink code engine diagnostic warning lamp (MIL)
  • Page 179 BLINK CODE Blink code engine diagnostic warning lamp (MIL) 22 Engine diagnostic warning lamp (MIL) flashes 2x long, 2x short Error level condition Engine speed signal - circuit fault Engine speed signal - input signal too low Engine speed signal - input signal too high Blink code engine diagnostic warning lamp (MIL) 23 Engine diagnostic warning lamp (MIL) flashes 2x long, 3x short...
  • Page 180 BLINK CODE Blink code engine diagnostic warning lamp (MIL) 26 Engine diagnostic warning lamp (MIL) flashes 2x long, 6x short Error level condition Sensor A reference voltage - input signal too low Sensor A reference voltage - input signal too high Blink code engine diagnostic warning lamp (MIL) 27 Engine diagnostic warning lamp (MIL) flashes 2x long, 7x short...
  • Page 181 BLINK CODE Blink code engine diagnostic warning lamp (MIL) 45 Engine diagnostic warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater - circuit fault Lambda sensor heater - short circuit to ground or open circuit Lambda sensor heater - input signal too high Blink code engine diagnostic warning lamp (MIL)

  • Page 182: Technical Data

    TECHNICAL DATA 23.1 Engine 23.1.1 RC 125 Design 1-cylinder 4-stroke engine, water-cooled Displacement 125 cm³ (7.63 cu in) Stroke 47.2 mm (1.858 in) Bore 58 mm (2.28 in) Compression ratio 12.8:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 22.5 mm (0.886 in)

  • Page 183: Rc 200

    TECHNICAL DATA 3rd gear 18:28 4th gear 21:26 5th gear 22:23 6th gear 24:22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 296 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0.8 mm (0.031 in) Spark plug...
  • Page 184 TECHNICAL DATA Valve diameter, exhaust 24 mm (0.94 in) Valve clearance, intake, cold 0.08… 0.12 mm (0.0031… 0.0047 in) Valve clearance, exhaust, cold 0.13… 0.17 mm (0.0051… 0.0067 in) Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring, 1 tapered compression piston ring, 1 oil scraper ring...

  • Page 185: Engine Tightening Torques

    TECHNICAL DATA Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm (0.04 in) Cooling Water cooling, permanent circulation of coolant by water pump Idle speed 1,450… 1,550 rpm Starting aid Electric starter 23.2 Engine tightening torques Oil nozzle 6 Nm (4.4 lbf ft) Loctite...
  • Page 186 TECHNICAL DATA Screw, locking lever 12 Nm (8.9 lbf ft) Loctite ® 243™ – Screw, oil filter cover (RC 125) 12 Nm (8.9 lbf ft) – Screw, oil filter cover (RC 200) 12 Nm (8.9 lbf ft) Loctite ® 243™...

  • Page 187: Capacities

    Loctite ® 243™ (RC 200) – Stud, exhaust flange 22 Nm (16.2 lbf ft) Cylinder head screw (RC 125) Step 1 Thread is oiled, head flat is greased 25 Nm (18.4 lbf ft) Step 2 50 Nm (36.9 lbf ft) –...

  • Page 188: Coolant

    TECHNICAL DATA 23.3.2 Coolant Coolant 1 l (1 qt.) Coolant ( p. 195) 23.3.3 Fuel Total fuel tank capacity, approx. 10 l (2.6 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 197) Fuel reserve, approx. 1.5 l (1.6 qt.) 23.4 Chassis Frame...

  • Page 189: Electrical System

    1,340±15 mm (52.76±0.59 in) Seat height, unloaded 820 mm (32.28 in) Ground clearance, unloaded 178 mm (7.01 in) Weight without fuel, approx. (RC 125) 140 kg (309 lb.) Weight without fuel, approx. (RC 200) 141.5 kg (312 lb.) Maximum permissible front axle load 125 kg (276 lb.)

  • Page 190: Tires

    Front tires Rear tires 110/70 R 17 M/C 54S TL 150/60 R 17 M/C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 90501000000 WP Suspension Fork Fork length 736 mm (28.98 in)

  • Page 191: Shock Absorber

    TECHNICAL DATA Fork oil 460 ml (15.55 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 196) 23.8 Shock absorber Shock absorber part number 90504010000 Shock absorber WP Suspension Spring preload Comfort 1 click Standard 4 clicks Sport 4 clicks Full payload 8 clicks Static sag...
  • Page 192 TECHNICAL DATA – Remaining screws, chassis 5 Nm (3.7 lbf ft) – Screw, ABS hose clamp (RC 125) 6 Nm (4.4 lbf ft) – Screw, anti-rotation lock, handlebar stub M5 4 Nm (3 lbf ft) – Screw, battery compartment 4 Nm (3 lbf ft) Screw, chain guard 7 Nm (5.2 lbf ft)
  • Page 193 TECHNICAL DATA – Screw, air filter box, on frame 6 Nm (4.4 lbf ft) – Screw, battery compartment 6 Nm (4.4 lbf ft) – Screw, brake fluid container, front brake 8 Nm (5.9 lbf ft) – Screw, brake fluid container, rear brake 7 Nm (5.2 lbf ft) Screw, brake line guide on bottom triple 7 Nm (5.2 lbf ft)
  • Page 194 – Screw, radiator air inlet, on frame 6 Nm (4.4 lbf ft) – Screw, radiator holder 6 Nm (4.4 lbf ft) Screw, rear ABS sensor wheel (RC 125) 6 Nm (4.4 lbf ft) Loctite ® 204™ – Screw, rear fender 7 Nm (5.2 lbf ft)
  • Page 195 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, chain guard 11 Nm (8.1 lbf ft) – Screw, engine bearer on frame 24 Nm (17.7 lbf ft) Loctite ® 243™ Screw, foot brake lever 17 Nm (12.5 lbf ft) Screw, front brake disc 30 Nm (22.1 lbf ft) Loctite...
  • Page 196 TECHNICAL DATA Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) Loctite ® 204™ – Lambda sensor M18x1.5 20 Nm (14.8 lbf ft)

  • Page 197: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 198 SUBSTANCES Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Partially synthetic engine oil Recommended supplier Motorex ® – Formula 4T Engine oil (SAE 10W/40) Standard/classification –...
  • Page 199 SUBSTANCES 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.

  • Page 200: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 201 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 202: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 203: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces...

  • Page 204: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 205: List Of Symbols

    LIST OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The engine diagnosis warning lamp (MIL) lights up red – The OBD (on-board diagnosis) has detected an emission- or safety-critical error. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system (optional).

  • Page 206: Index

    INDEX INDEX Brake linings front brake, checking ......109 ABS ........105 rear brake, checking .
  • Page 207 INDEX average fuel consumption 1/average fuel consumption 2 menu ........47 Electric starter button .
  • Page 208 INDEX Front rider's seat Horn button ........23 mounting .
  • Page 209 INDEX Rear sprocket checking ........92 Oil filter Rear wheel changing .
  • Page 210 INDEX removing ........100 Tire condition checking ........128 Side stand .
  • Page 211 *3213406en* 3213406en 11/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

Rc 200

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