KTM RC 125 2022 Manual

SETUP INSTRUCTIONS 2022

RC 125

Art. no. 3214678en

INTRODUCTION

*3214678en*

3214678en

04/2022

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right

to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,

without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-

tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-

ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that

does not belong to the regular scope of supply.

These setup instructions were written to correspond to the latest state of this model series. We reserve the right

to make modifications in the interest of technical advancement without at the same time updating these setup

instructions.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop

are not specified here. It is assumed that the work will be performed by a fully trained mechanic.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

RC 125 EU (F5003V1, F5003V2)

RC 125 JP (F5086V3, F5086V4)

RC 125 UK (F5022V1, F5022V2)

1 MEANS OF REPRESENTATION

1.1 Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SETUP 2

2.1 Transport mode

H02713-01

This vehicle was blocked for transport in the software.

To operate the vehicle, the vehicle electronics must be enabled.

This process is conducted during initial setup in KTM Dealer.net.

Enabling ensures that the initial setup in KTM Dealer.net is docu-

mented.

Enabling can be performed either temporarily, e.g. for a test ride,

or permanently for vehicle handover.

Info

Make sure that the vehicle is permanently enabled before

handing it over to the customer.

2.2 Diagnostics connector

S05281-10

Diagnostics connector 1is located under the front rider's seat.

2.3 Unpacking and setting up the vehicle

Preliminary work

–Remove the straps and the box.

H05199-01

Main work

–Remove the adhesive tape in the upper area of the motorcycle.

–Roll down the film at the sides.

Info

To avoid damaging the motorcycle during unpacking,

leave the other films on the vehicle until you have fin-

ished work on the vehicle.

–Remove the separate enclosure and unpack it. Check the sepa-

rate enclosure for completeness.

Info

The procedure for missing components is described in

the Customer Service Manual.

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the Customer Service Manual.

2 SETUP

V02670-01

–Turn the rear mirror to the correct position on both sides.

H03807-10

–Make sure that the clutch cable is attached to the clutch

release lever and secured.

–Check the clutch lever play. ( p. 6)

–Check the play in the throttle cable. ( p. 7)

H05199-01

–Carefully remove the bracket from the link fork.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tension belts around the lower

triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the pallet.

Warning

Risk of injury Battery acid and battery gases cause

serious chemical burns.

–Keep 12 V batteries out of the reach of children.

–Wear suitable protective clothing and safety

glasses.

–Avoid contact with battery acid and battery gases.

–Keep sparks or open flames away from the 12 V

battery.

–Only charge 12 V batteries in well-ventilated

rooms.

–Rinse the affected area immediately with plenty of

water in the event of contact with the skin.

–Rinse eyes with water for at least 15 minutes and

consult a doctor immediately if battery acid and

battery gases get into the eyes.

–Fill the 12 V battery.

Info

Read the notes in the 12 V battery accessory pack.

–Charge the 12-V battery. ( p. 9)

SETUP 2

Guideline

The 12-V battery must be fully charged before it is handed

over to the customer.

Info

The first charging process may take longer with a new

12-V battery.

V02669-01

–Remove the front rider's seat. ( p. 7)

–Store the tool set below the seat.

–Remove spare key and KEYCODECARD and keep in a safe place

for the handover.

–Remove the fuel tank cover. ( p. 8)

–Install the 12-V battery. ( p. 11)

–Remove the remaining film, padding, the corrugated card-

board, and the other packaging material.

–Mount the fuel tank cover. ( p. 9)

–Mount the front rider's seat. ( p. 8)

–Refuel. ( p. 14)

–Prepare the vehicle according to the specifications in

KTM Dealer.net for handover to the customer.

Info

Transport mode must be deactivated to be able to start

the motorcycle.

3 WORK

3.1 Checking the clutch lever play

Note

Clutch damage If there is no free travel by the clutch lever, the clutch will begin to slip.

–Check the free travel of the clutch lever each time before using the motorcycle.

–Adjust the free travel of the clutch lever when necessary in accordance with the specification.

V02680-01

–Check the clutch lever for smooth operation.

–Move the handlebar to the straight-ahead position.

–Pull the clutch lever until resistance is perceptible, and deter-

mine the play in the clutch lever A.

Clutch lever play A1 … 3 mm (0.04 …

0.12 in)

» If the clutch lever play does not meet the specified value:

–Adjust play in the clutch lever. ( p. 6)

–Move the handlebar to and fro over the entire steering range.

The clutch lever play must not change.

» If the clutch lever play changes:

–Check the routing of the clutch cable.

3.2 Adjusting play in the clutch lever

V02681-10

–Move the handlebar to the straight-ahead position.

–Push back sleeve 1.

–Loosen lock nut 2.

–Adjust the play in the clutch level Aby turning adjusting

screw 3.

Guideline

Clutch lever play A1 … 3 mm (0.04 …

0.12 in)

–Tighten lock nut 2.

–Position bellows 1.

WORK 3

3.3 Checking the play in the throttle cable

400192-11

–Check the throttle grip for smooth operation.

–Move the handlebar to the straight-ahead position. Turn the

throttle grip back and forth slightly and determine the play in

throttle cable A.

Throttle cable play A3 … 5 mm (0.12 … 0.2 in)

» If the throttle cable play does not meet the specified value:

–Adjust the play in the throttle cable. ( p. 7)

Danger

Danger of poisoning Exhaust gases are toxic and inhal-

ing them may result in unconsciousness and death.

–Always make sure there is sufficient ventilation

when running the engine.

–Use effective exhaust extraction when starting or

running the engine in an enclosed space.

–Start the engine and let it run at idle speed. Move the handle-

bar to and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes:

–Check the throttle cable routing.

3.4 Adjusting the play in the throttle cable

V02544-10

–Move the handlebar to the straight-ahead position.

–Push back sleeve 1.

–Loosen lock nut 2.

–Adjust the play in the throttle cable by turning barrel

adjuster 3.

Guideline

Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)

–Tighten lock nut 2.

–Slide on sleeve 1.

3.5 Removing the front rider's seat

V02660-10

–Insert the ignition key in seat lock 1and turn it clockwise.

–Raise the rear of the front rider's seat, pull it toward the rear,

and remove it upward.

–Remove the ignition key from the seat lock.

3 WORK

3.6 Mounting the front rider's seat

H04979-10

–Attach recesses 1on the front rider's seat to the fuel tank,

push the front rider's seat forward, and lower at the rear.

The pin 2locks audibly in place.

–Check that the front rider's seat is mounted correctly.

3.7 Removing the fuel tank cover

Preparatory work

–Remove the front rider's seat. ( p. 7)

V02492-10

Main work

–Remove screws 1.

V02493-10

–Pull the fuel tank cover from holding lugs 2.

–Pull holding lugs 3out of the brackets.

–Pull the fuel tank cover off towards the rear and take off

upwards.

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