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KTM RC 125, Owner'S Manual

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KTM RC 125 Owner'S Manual Download Page 88

12

SERVICE WORK ON THE CHASSIS

86

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.

–

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

The service life of the chain depends largely on its maintenance.

Preparatory work

–

Raise the motorcycle with the rear wheel stand. (

p. 78)

Summary of Contents for RC 125

Page 1: ...OWNER S MANUAL 2016 RC 125 RC 200 Art no 3213406en...

Page 2: ......

Page 3: ...differences due to develop ments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical spec...

Page 4: ...nternational quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service KTM Sportmotorcycle Gm...

Page 5: ...right example 18 5 SERIAL NUMBERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Engine number 21 5 4 Key number 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4...

Page 6: ...hen preparing for use 60 9 2 Starting 61 9 3 Starting off 63 9 4 Shifting riding 63 9 5 Applying the brakes 66 9 6 Stopping parking 68 9 7 Transport 69 9 8 Refueling 70 10 SERVICE SCHEDULE 72 10 1 Add...

Page 7: ...21 14 4 Installing the rear wheel 123 14 5 Checking the rear hub rubber dampers 127 14 6 Checking the tire condition 128 14 7 Checking the tire air pressure 129 15 ELECTRICAL SYSTEM 131 15 1 Removing...

Page 8: ...OOTING 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 Engine oil 185 23 3 2 Coolant 186 2...

Page 9: ...th 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 optima...

Page 10: ...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 det...

Page 11: ...version only 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the te...

Page 12: ...Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law pro...

Page 13: ...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...

Page 14: ...s In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and...

Page 15: ...hen will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Page 16: ...ironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as...

Page 17: ...inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much lo...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example L02145 10...

Page 19: ...VIEW OF VEHICLE 17 1 Horn button p 23 1 Light switch p 24 1 High beam flasher button p 24 1 Turn signal switch p 25 2 Clutch lever p 22 3 Filler cap 4 Seat lock p 29 5 Side stand p 33 6 Shift lever p...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example L02146 10...

Page 21: ...1 Grab handles p 30 2 Tool set p 30 3 Ignition steering lock p 26 4 Emergency OFF switch p 25 4 Electric starter button p 26 5 Throttle grip p 23 6 Hand brake lever p 22 7 Passenger footrests p 31 8 F...

Page 22: ...ERS 20 5 1 Chassis number 402175 10 The chassis number is stamped on the right side of the frame under the seat 5 2 Type label 0 0 1 1 402174 10 The type label is on the right of the frame behind the...

Page 23: ...0 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 10 The key number can be found on the KEYCODECARD Info You need the key number to order a...

Page 24: ...ever L02111 10 The clutch lever is fitted on the left side of the handlebar 6 2 Hand brake lever L02112 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged...

Page 25: ...rottle grip is fitted on the right side of the handlebar 6 4 Horn button L02113 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn butt...

Page 26: ...re 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 6 6 High beam flasher button L02113 12 The high beam flash...

Page 27: ...the right The turn signal switch returns automatically to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 6 8 Emergency OFF switch L0...

Page 28: ...teering lock L02115 01 The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a n...

Page 29: ...400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Steering is no longer possible 6 12...

Page 30: ...occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Chan...

Page 31: ...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 Close the filler ca...

Page 32: ...10 The tool set is in the storage compartment under the seat 6 17 Grab handles L02119 10 The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold ont...

Page 33: ...r 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 6 19 Shift lever 401...

Page 34: ...can be seen in the photograph The neutral or idle position is between the first and second gears 6 20 Foot brake lever 402177 10 Foot brake lever is located in front of the right footrest The foot bra...

Page 35: ...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 The vehicle can be leaned on th...

Page 36: ...7 COMBINATION INSTRUMENT 34 7 1 Overview 401685 10 1 Display p 41 2 Function buttons p 39 3 Info display p 45 4 Indicator lamps p 40...

Page 37: ...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 i...

Page 38: ...INSTRUMENT 36 7 3 Warning notes 401309 01 Low Oil Pressure appears on the info display if the oil pressure is too low 401310 01 Low Fuel Level appears on the info display if the fuel level reaches the...

Page 39: ...oolant temperature rises above the specified value Coolant temperature 125 C 257 F 401312 01 Side Stand Down appears on the info display if the side stand is folded down 401313 01 Low Battery appears...

Page 40: ...rvice 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...

Page 41: ...e total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the S...

Page 42: ...The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The i...

Page 43: ...minute The gear display shows the engaged gear The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display shows...

Page 44: ...7 COMBINATION INSTRUMENT 42 7 7 Filling level display in fuel tank 401292 01 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank...

Page 45: ...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 war...

Page 46: ...s 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 Up to...

Page 47: ...7 COMBINATION INSTRUMENT 45 7 10 Info display 401291 10 Various warning notes appear on info display If the general warning lamp lights up the corresponding warning note is shown on the info display...

Page 48: ...The riding time and average speed are displayed in this menu Info If the ignition was switched off for over 60 minutes the display is reset to 0 Press the SET button briefly Next display mode on the...

Page 49: ...ge fuel consumption 1 average fuel consumption 2 menu 401466 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press...

Page 50: ...he SET button briefly and repeatedly until the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu Info The a...

Page 51: ...ired info display appears This menu shows the distance to the next service and the range Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is disp...

Page 52: ...e desired info display appears The range and the riding time are displayed in this menu Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displ...

Page 53: ...ary 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 Info This value is reta...

Page 54: ...stops TRIP 1 is always running and counts up to 999 9 Press the SET button for 5 10 seconds Display of TRIP 1 is reset Press the MODE but ton Next display mode on the display 7 19 Distance menu 2 TRIP...

Page 55: ...de on the display 7 20 Setting kilometers or miles Info Make the country specific setting Condition The ignition is on The motorcycle is stationary 401303 01 Press the MODE button briefly and repeated...

Page 56: ...e minutes display using the SET button Press the MODE and SET buttons for 5 10 seconds The time is set 7 22 Adjusting the shift speed RPM 1 Condition The ignition is on The motorcycle is stationary 40...

Page 57: ...efly and repeatedly until TRIP 2 appears on the display Press the SET button for 5 10 seconds The display RPM 2 appears Info The engine speed can be set at intervals of 50 RPM 2 is the engine speed ab...

Page 58: ...due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Dange...

Page 59: ...efore making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the...

Page 60: ...arning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of a...

Page 61: ...f 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...

Page 62: ...p 110 Check the front brake linings p 109 Check the rear brake linings p 113 Check the brake system function Check the coolant level in the compensating tank p 148 Check for chain dirt accumulation p...

Page 63: ...cle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note E...

Page 64: ...hts 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 When starting D...

Page 65: ...ltaneously open the throttle carefully Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral 9 4 Shifting rid...

Page 66: ...the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of d...

Page 67: ...e 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 worksho...

Page 68: ...the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents...

Page 69: ...e When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or sl...

Page 70: ...n 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 9 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized pers...

Page 71: ...e ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flo...

Page 72: ...he 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 The fuel...

Page 73: ...help Only refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water...

Page 74: ...ange the engine oil and oil filter clean the oil screen p 160 Check the brake discs p 106 Check the front brake linings p 109 Check the rear brake linings p 113 Check the tire condition p 128 Check th...

Page 75: ...es for damage and routing without sharp bends Check the valve clearance Check the valve clearance change the spark plugs Change the front brake fluid Change the rear brake fluid Check the steering hea...

Page 76: ...earing Check the wheel bearings Grease all moving parts e g side stand hand lever chain and check for smooth operation Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking le...

Page 77: ...of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compro...

Page 78: ...ut holding the threaded rod Adjust the shift lever by turning shift rod Guideline Shift rod adjustment range 150 162 mm 5 91 6 38 in Info Make the same adjustments on both sides At least five screw th...

Page 79: ...11 TUNING THE CHASSIS 77 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: ...wheel stand Insert the adapter in the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lif...

Page 81: ...ean the vehicle on the side stand 12 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even...

Page 82: ...9055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 12 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll a...

Page 83: ...boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Da...

Page 84: ...ver time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the...

Page 85: ...the front rider s seat pull it toward the rear and remove it upward Remove the ignition key from the seat lock 12 7 Mounting the front rider s seat 401921 10 Attach recesses on the front rider s seat...

Page 86: ...work Remove the front rider s seat p 83 L02191 10 Main work Remove screw with the washer Lift and take off the passenger seat 12 9 Mounting the passenger seat G01073 10 Main work Position the passenge...

Page 87: ...me loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up Check that the passenger seat is correctly mounted Finishin...

Page 88: ...or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental d...

Page 89: ...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 i...

Page 90: ...g guard press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ e...

Page 91: ...on and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loos...

Page 92: ...t so that the markings on the left and right chain adjusters are in the same position relative to the refer ence marks The rear wheel is then correctly aligned Info The upper chain section must be tau...

Page 93: ...that the markings on the left and right chain adjusters are in the same position relative to the refer ence marks The rear wheel is then correctly aligned Info The upper chain section must be taut Cha...

Page 94: ...ain rear sprocket and engine sprocket 100132 10 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 rea...

Page 95: ...20 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 301 6 mm...

Page 96: ...ard has lost material due to wear to the extent that in area the drilled hole of screw is visible from above Change the chain sliding guard Check that the chain sliding guard is firmly seated If the c...

Page 97: ...12 SERVICE WORK ON THE CHASSIS 95 L02144 10 Main work Pull loop toward the rear Pull battery cover forward and remove toward the top...

Page 98: ...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 83 12 17 Removing the front spoiler Prep...

Page 99: ...12 SERVICE WORK ON THE CHASSIS 97 G00976 12 Remove screw G00977 12 Remove screws G01721 13 Remove screw Remove screw Take off the front spoiler...

Page 100: ...and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 9 Nm 6 6 lbf ft Mount and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 9 Nm 6 6...

Page 101: ...ighten screw Guideline Screw front spoiler right on footrest bracket M6 7 Nm 5 2 lbf ft G01029 11 Mount and tighten screws Guideline Screw front spoiler M6 7 Nm 5 2 lbf ft Finishing work Install the l...

Page 102: ...12 SERVICE WORK ON THE CHASSIS 100 12 19 Removing the left side cover G00963 10 Remove screws Remove screws Pull off holding lug in area G00964 10 Remove expanding rivet...

Page 103: ...12 SERVICE WORK ON THE CHASSIS 101 L02200 10 Swing the side cover outward Pull hose out of hose guide Take off the side cover 12 20 Installing the left side cover L02200 11 Position hose in hose guide...

Page 104: ...nd tighten screws Guideline Screw side cover M6 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 Mount and tighten screws Guideline Screw...

Page 105: ...12 SERVICE WORK ON THE CHASSIS 103 12 21 Removing the right side cover L02178 10 Remove screws Remove screws Pull off holding lug in area L02185 10 Remove expanding rivet Take off the side cover...

Page 106: ...side cover Mount and tighten screws Guideline Screw side cover M6 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 Mount and tighten scr...

Page 107: ...cified tire air pressure Service work and repairs must be performed professionally Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when...

Page 108: ...for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when t...

Page 109: ...elow 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 Warning Dan...

Page 110: ...les If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake flu...

Page 111: ...spilt brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediatel...

Page 112: ...ear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings C...

Page 113: ...Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid p 111 13 7 Adding rear brake fluid Warning Danger of accidents Failure of the b...

Page 114: ...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 Environ...

Page 115: ...with water L02137 10 RC 125 Stand the vehicle upright Remove screw cap with membrane Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 195 Refit screw cap with membrane Info Clean up overflowed or...

Page 116: ...r minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is wear or tea...

Page 117: ...2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 115 Reconnect spring 13 10 Adjusting the free travel of the foot brake lever Warning Danger of acc...

Page 118: ...11 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 Hold screw and...

Page 119: ...screw about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Alwa...

Page 120: ...educed braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front whee...

Page 121: ...le and screw Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M8 26 Nm 19 2 lbf ft Operate t...

Page 122: ...t the wheel spindle The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M8 26 Nm 19 2 lbf ft Position wheel speed sensor in the drill hole Mount and...

Page 123: ...fork stub M8 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 78 14 3 Removing the rear wheel Preparatory work R...

Page 124: ...ter Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down i...

Page 125: ...t Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Pull the rear wheel back and take it out...

Page 126: ...heel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 198 I...

Page 127: ...In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 90 N...

Page 128: ...left and right chain adjusters in the same position Mount nut and washer Push the rear wheel forward so that the chain adjusters are in contact with the screws and tighten nut Guideline In order for t...

Page 129: ...02153 10 Main work Check bearing If the bearing is damaged or worn Change the rear wheel bearing Check the rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are...

Page 130: ...nger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of...

Page 131: ...the tires Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufacture...

Page 132: ...en 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 Rear 2 2 bar 32 psi If the tire air pressure do...

Page 133: ...cid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the...

Page 134: ...th a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 15 2 Installing the battery L02157 10...

Page 135: ...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 an...

Page 136: ...rging current shortens the battery s service life If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity...

Page 137: ...tor With this device you cannot overcharge the battery Info Never remove lid Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage a...

Page 138: ...it of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the front rider s seat p 83 Remove the...

Page 139: ...ap and remove fuse 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 Use spare fuses with...

Page 140: ...ront rider s seat p 83 Remove the battery cover p 94 L02202 10 Main work RC 200 Open fuse box cover Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A start auxiliary relay alarm sy...

Page 141: ...fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 187 Fuse 75011088015 p 188 Fuse 75011088030 p 1...

Page 142: ...ignal high beam low beam parking light tail light license plate lamp Fuse 7 10 A combination instrument control unit Fuse 8 5 A ABS control unit Fuse 9 10 A auxiliary equipment Fuse 10 10 A auxiliary...

Page 143: ...oning properly Close the fuse box cover Finishing work Mount the battery cover p 96 Mount the front rider s seat p 83 15 6 Changing the low beam bulb Note Damage to reflector Reduced brightness Grease...

Page 144: ...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 188 L02166 10 Position the...

Page 145: ...and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine L02162 10 Main work Turn socket counterclockwise Pull the socket with high beam bul...

Page 146: ...height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle perpendicular to the wall at a distance from the...

Page 147: ...nder the first mark Guideline Distance 5 cm 2 in Position the vehicle perpendicular to the wall at a distance from the wall and switch on the high beam Guideline Distance 5 m 16 ft The rider with lugg...

Page 148: ...counterclockwise to reduce the headlight range Finishing work Check the low beam headlight adjustment p 144 15 11 Adjusting the headlight range of the high beam L02163 10 Main work Adjust the beam di...

Page 149: ...he 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 co...

Page 150: ...so reduce the cooling effect 16 2 Checking 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 remo...

Page 151: ...contaminated with coolant Keep coolant out of reach of children Condition The engine is cold The radiator is completely full M00464 10 Stand the motorcycle upright on a horizontal surface Check the co...

Page 152: ...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 im...

Page 153: ...eze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct...

Page 154: ...alth 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...

Page 155: ...he 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...

Page 156: ...us 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 contami...

Page 157: ...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 e...

Page 158: ...16 COOLING SYSTEM 156 Install the right side cover p 104...

Page 159: ...pecifications Adjust the play in the throttle cable p 158 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always...

Page 160: ...e clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and determine the play in the clutch lever Clutch lever play...

Page 161: ...utch cable 17 4 Adjusting the clutch cable play L02155 10 Move the handlebar to the straight ahead position Push back sleeve Loosen lock nut Adjust the play in the clutch level by turning adjusting sc...

Page 162: ...el is below the marking Add the engine oil p 163 When the engine oil level is above the marking Correct the engine oil level 18 2 Changing the engine oil and oil filter cleaning the oil screen Warning...

Page 163: ...ide stand on a horizontal surface L02168 10 Main work Place a suitable container under the engine Remove oil drain plug with the O ring Remove oil screen with the O ring Completely drain the engine oi...

Page 164: ...sealing surface L02170 10 Insert oil filter 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 M5 8 Nm 5 9 lbf ft...

Page 165: ...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 e...

Page 166: ...engine oil If appropriate change the engine oil Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousne...

Page 167: ...malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in...

Page 168: ...ue to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up Info The heat produc...

Page 169: ...for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt c...

Page 170: ...ll 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 gr...

Page 171: ...g for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 198 Refuel p 70 Clean the motorcycle p 165 Change the engine oil and oil filter clean the oil screen p...

Page 172: ...ng the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 20 2 Preparing for use af...

Page 173: ...t 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 ve...

Page 174: ...ain Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil le...

Page 175: ...ment shows nothing on the display Fuse 7 is blown RC 125 Change the fuses of individual power consumers p 138 Set the clock p 54 Fuse 2 blown RC 200 Change the fuses of individual power consumers p 13...

Page 176: ...warning lamp MIL 09 Engine diagnostic warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor input signal too low Manifold absolute pressure sensor input signal too...

Page 177: ...cuit fault Fuel tank sensor short circuit to ground Fuel tank sensor short circuit to plus Blink code engine diagnostic warning lamp MIL 15 Engine diagnostic warning lamp MIL flashes 1x long 5x short...

Page 178: ...dition Engine diagnosis warning lamp MIL circuit fault Engine diagnosis warning lamp MIL short circuit to ground Engine diagnosis warning lamp MIL short circuit to plus Blink code engine diagnostic wa...

Page 179: ...short Error level condition Travel speed sensor measurement range or power problem Blink code engine diagnostic warning lamp MIL 24 Engine diagnostic warning lamp MIL flashes 2x long 4x short Error le...

Page 180: ...evel condition Sensor B reference voltage input signal too low Sensor B reference voltage input signal too high Blink code engine diagnostic warning lamp MIL 33 Engine diagnostic warning lamp MIL flas...

Page 181: ...ensor 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 49 Engine diagnostic wa...

Page 182: ...n 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 l...

Page 183: ...lug electrode gap 0 8 mm 0 031 in 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 r...

Page 184: ...raper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mechanically activated Transmission 6 gear claw shifted Transmi...

Page 185: ...aining bracket stator cable M5 8 Nm 5 9 lbf ft Loctite 243 Screw stator M5 8 Nm 5 9 lbf ft Loctite 243 Cylinder head screw M6 12 Nm 8 9 lbf ft Nut water pump impeller M6 10 Nm 7 4 lbf ft Loctite 243 P...

Page 186: ...motor M6 12 Nm 8 9 lbf ft Screw timing chain tensioner M6 12 Nm 8 9 lbf ft Screw timing chain tensioning rail M6 12 Nm 8 9 lbf ft Loctite 243 Screw valve cover M6 12 Nm 8 9 lbf ft Screw water pump cov...

Page 187: ...44 3 lbf ft Loctite 243 Screw cylinder head RC 200 M10 Step 1 25 Nm 18 4 lbf ft Step 2 50 Nm 36 9 lbf ft Thread is oiled head flat is greased Water temperature sensor M10 14 Nm 10 3 lbf ft Spark plug...

Page 188: ...Chassis Frame Lattice frame of steel tubes powder coated Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four pot brake caliper Rear Disc brake with single piston br...

Page 189: ...40 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 M...

Page 190: ...LED Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 23 6 Tires Front tires Rear tires 110 70 R 17 M C 54S TL MRF revz FC 150 60 R 17 M C 66S TL M...

Page 191: ...14 mm 0 55 in Riding sag 45 50 mm 1 77 1 97 in Fitted length 300 mm 11 81 in 23 9 Chassis tightening torques Exhaust clamp 19 Nm 14 lbf ft Screw chain guard EJOT PT K60x30 4 Nm 3 lbf ft Remaining nuts...

Page 192: ...ft Loctite 243 Screw side stand switch M5 5 Nm 3 7 lbf ft Loctite 243 Screw tail end lower part M5 4 Nm 3 lbf ft Cap bolt footrest M6 9 Nm 6 6 lbf ft Nut foot brake lever adjustment M6 9 Nm 6 6 lbf f...

Page 193: ...ensating tank M6 9 Nm 6 6 lbf ft Screw engine sprocket cover on frame M6 7 Nm 5 2 lbf ft Screw foot brake cylinder M6 9 Nm 6 6 lbf ft Loctite 243 Screw footrest bracket M6 7 Nm 5 2 lbf ft Screw front...

Page 194: ...6 6 Nm 4 4 lbf ft Screw radiator holder M6 6 Nm 4 4 lbf ft Screw rear ABS sensor wheel RC 125 M6 6 Nm 4 4 lbf ft Loctite 204 Screw rear fender M6 7 Nm 5 2 lbf ft Screw retaining bracket EFI control un...

Page 195: ...tite 243 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw shift lever M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 lbf ft Screw front brake caliper M8x1 30 Nm 22 1...

Page 196: ...23 TECHNICAL DATA 194 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: ...AKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior a...

Page 198: ...tion JASO T903 MA p 200 SAE p 200 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties P...

Page 199: ...8 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...

Page 200: ...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...

Page 201: ...ex 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 Recommend...

Page 202: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 203: ...27 INDEX OF SPECIAL TERMS 201 ABS ABS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces...

Page 204: ...28 LIST OF ABBREVIATIONS 202 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 205: ...rompt intervention Active driving aids are also represented by yellow or orange symbols The general warning lamp lights up yellow An operating safety warning message was detected This is also shown in...

Page 206: ...ng 108 rear brake adding 111 Brake fluid level front brake checking 107 rear brake checking 110 Brake linings front brake checking 109 rear brake checking 113 Brakes 66 Brakes applying 66 C Capacity c...

Page 207: ...peed menu 46 service range menu 49 total distance menu ODO 51 warning notes 36 Coolant draining 153 Coolant level checking 150 compensating tank checking 148 compensating tank correcting 152 Cooling s...

Page 208: ...sting 146 High beam bulb changing 143 High beam flasher button 24 High beam headlight adjustment checking 145 Horn button 23 I Ignition lock 26 Implied warranty 14 Indicator lamps 40 K Key number 21 K...

Page 209: ...ecks and maintenance when preparing for use 60 Protective clothing 12 R Rear hub rubber dampers checking 127 Rear sprocket checking 92 Rear wheel installing 123 removing 121 Riding 63 starting off 63...

Page 210: ...rical system 187 engine 180 engine tightening torques 183 fork 188 shock absorber 189 tires 188 Throttle grip 23 Time adjusting 54 Tire air pressure checking 129 Tire condition checking 128 Tool set 3...

Page 211: ...3213406en 3213406en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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