OWNER'S MANUAL 2015 RC 125 EU RC 200 EU RC 200 ASIA RC 200 MY Art. no.
DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR KTM CUSTOMER We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Chassis number ( p. 20) Engine number ( p. 21) Key number ( Dealer's stamp p.
DEAR KTM CUSTOMER 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.
TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 MEANS OF REPRESENTATION ........................................ 7 1.1 Symbols used ...................................................... 7 1.2 Formats used....................................................... 7 SAFETY ADVICE.............................................................. 8 2.1 Use definition...................................................... 8 2.2 Safety advice....................................................... 8 2.
TABLE OF CONTENTS 7.7 7.8 7.9 7.10 7.11 7.12 8 9 Filling level display in fuel tank ........................... TRIP F display ................................................... Coolant temperature indicator ............................. Info display ....................................................... Riding time/average speed menu ......................... Average speed/average fuel consumption 1 menu................................................................ 7.
TABLE OF CONTENTS 12.14 Removing the battery cover ................................. 92 12.15 Mounting the battery cover.................................. 94 12.16 Removing the front spoiler .................................. 94 12.17 Fitting front spoiler ............................................ 96 12.18 Removing the left side cover ............................ 98 12.19 Installing the left side cover ............................ 99 12.20 Removing the right side cover ........................ 101 12.
TABLE OF CONTENTS 18.2 19 20 21 22 23 24 25 Changing the engine oil and oil filter, cleaning the oil screen ............................................... 18.3 Adding engine oil ............................................. CLEANING, CARE ....................................................... 19.1 Cleaning the motorcycle ................................... 19.2 Checks and maintenance steps for winter operation......................................................... STORAGE ..........................
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). 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.
2 SAFETY ADVICE 2.1 Use definition 8 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. 2.2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully.
2 SAFETY ADVICE 2.3 Degrees of risk and symbols 9 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.
2 SAFETY ADVICE 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 2.5 10 Safe operation Danger Danger of accidents Danger arising from the rider's judgement being impaired.
2 SAFETY ADVICE 2.6 Protective clothing 11 Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – 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. 2.
2 SAFETY ADVICE 2.9 Owner's Manual 12 It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then 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 needed.
3 IMPORTANT NOTES 3.1 Guarantee, warranty 13 The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
3 IMPORTANT NOTES 14 Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperative that you adhere to the stipulated run-in times and service intervals.
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4 VIEW OF VEHICLE 4.
4 VIEW OF VEHICLE 1 Horn button ( p. 23) 1 Light switch ( p. 24) 1 High beam flasher button ( 1 Turn signal switch ( 2 Clutch lever ( 3 Filler cap 4 Seat lock ( 5 Side stand ( p. 33) 6 Shift lever ( p. 31) p. 22) p. 29) p. 25) 17 p.
4 VIEW OF VEHICLE 4.
4 VIEW OF VEHICLE 1 Grab handles ( p. 30) 2 Tool set ( 3 Ignition/steering lock ( 4 Emergency OFF switch ( 4 Electric starter button ( 5 Throttle grip ( 6 Hand brake lever ( 7 Passenger footrests ( 8 Foot brake lever ( p. 30) p. 26) p. 25) p. 26) p. 23) p. 22) p. 31) p.
5 SERIAL NUMBERS 5.1 Chassis number 20 The chassis number is stamped on the right side of the frame under the seat. 402175-10 5.2 Type label The type label 1 0 402174-10 is on the right of the frame behind the steering head.
5 SERIAL NUMBERS 5.3 Engine number 21 The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10 5.4 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.
6 CONTROLS 6.1 Clutch lever 22 The clutch lever is fitted on the left side of the handlebar. L02111-10 6.2 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.
6 CONTROLS 6.3 Throttle grip 23 The throttle grip is fitted on the right side of the handlebar. The horn button is fitted on the left side of the handlebar. L02112-11 6.4 Horn button Possible states • Horn button • Horn button L02113-10 in neutral position pressed – The horn is operated in this position.
6 CONTROLS 6.5 Light switch 24 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. L02113-11 6.6 High beam flasher button The high beam flasher button is fitted on the left side of the handlebar.
6 CONTROLS 6.7 Turn signal switch 25 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 – Turn signal switch pressed to the right. The turn signal switch returns automatically to the central position after use. L02113-13 6.
6 CONTROLS 6.9 Electric starter button 26 The electric starter button Possible states • Electric starter button • Electric starter button is fitted on the right side of the handlebar. in basic position pressed – In this position, the electric starter is actuated. L02114-11 6.10 Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp.
6 CONTROLS 6.11 Locking the steering 27 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. – Insert the key into the ignition/handlebar lock, press in, and turn to the left. Remove the key. Steering is no longer possible. 400732-01 6.12 Unlocking the steering – Insert the key into the ignition/handlebar lock, press in, and turn to the right.
6 CONTROLS 6.13 Opening the filler cap 28 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. – The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard.
6 CONTROLS 29 – 6.14 Remove the ignition key. 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 clothing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water. – Close the filler cap. – Push down the filler cap until the lock engages. L02117-01 6.15 Seat lock The seat lock is located to the left of the seat.
6 CONTROLS 6.16 Tool set 30 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.
6 CONTROLS 6.18 Passenger footrests 31 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 Shift lever 401950-10 is mounted on the left side of the engine.
6 CONTROLS 32 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.
6 CONTROLS 6.21 Side stand 33 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. 402029-10 Possible states • Side stand folded out – The vehicle can be leaned on the side stand. The safety start system is active. • Side stand folded in – This position is mandatory for all trips.
7 COMBINATION INSTRUMENT 7.1 Overview 401685-10 34 1 Display ( 2 Function buttons ( p. 41) 3 Info display ( 4 Indicator lamps ( p. 39) p. 45) p.
7 COMBINATION INSTRUMENT 7.2 Activation and test 35 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. The READY TO RACE >> logo appears on the info display. The display then changes to the last selected mode.
7 COMBINATION INSTRUMENT 7.3 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.
7 COMBINATION INSTRUMENT 37 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. Battery voltage 401313-01 10.
7 COMBINATION INSTRUMENT 38 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.
7 COMBINATION INSTRUMENT 7.4 Function buttons 39 You can change the display mode with the MODE button . Possible display modes are 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 SET button changes the info display to the next display mode.
7 COMBINATION INSTRUMENT 7.5 Indicator lamps 40 Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The engine diagnosis warning lamp (MIL) lights up red – The OBD (onboard diagnosis) has detected an emission- or safety-critical error. The shift warning lights up/flashes red – The set shift speed has been reached. The idling speed indicator lamp lights up green – The transmission is shifted to idle.
7 COMBINATION INSTRUMENT 7.6 Display The The The The The The The 41 speed is shown in kilometers per hour km/h or in miles per hour mph. tachometer shows the engine speed in revolutions per minute. gear display shows the engaged gear. coolant temperature appears in segment . time appears in segment . filling level in the fuel tank is displaced in segment . info display shows additional information. Info After reconnecting the battery or changing the fuse, the time must be reset.
7 COMBINATION INSTRUMENT 7.7 Filling level display in fuel tank 42 The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank.
7 COMBINATION INSTRUMENT 7.8 TRIP F display 43 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 and the warning note Low Fuel Level appears on the info display.
7 COMBINATION INSTRUMENT 7.9 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 – Up to three bars light up. • Engine warm – Four to ten bars light up. • Engine hot – Eleven to thirteen bars light up.
7 COMBINATION INSTRUMENT 7.10 Info display 45 Various warning notes appear on info display . If the general warning lamp lights up, the corresponding warning note is shown on the info display.
7 COMBINATION INSTRUMENT 7.11 Riding time/average speed menu 46 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. 401334-01 • 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. Info If the ignition was switched off for over 60 minutes, the display is reset to 0. Press the SET button briefly. 7.
7 COMBINATION INSTRUMENT 47 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. Press the SET button briefly. 7.
7 COMBINATION INSTRUMENT Press the SET button briefly. 7.14 48 Next display mode on the info display Average fuel consumption 2/service menu Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. 401467-01 • The motorcycle is moving. – Press the 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.
7 COMBINATION INSTRUMENT 7.15 Service/range menu 49 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. 401468-01 • 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. Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
7 COMBINATION INSTRUMENT 7.16 Range/riding time menu 50 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. 401469-01 • 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. Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
7 COMBINATION INSTRUMENT 7.17 Total distance menu ODO 51 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. 401303-01 • 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 retained, even if the battery is disconnected and/or the fuse blows. Press the MODE button. 7.
7 COMBINATION INSTRUMENT 52 TRIP 1 shows the distance covered since the last reset. For example, the distance from one refueling stop to the next. TRIP 1 is always running and counts up to 999.9. 7.19 Press the SET button for 5 - 10 seconds. Display of TRIP 1 is reset Press the MODE button. Next display mode on the display Distance menu 2 TRIP 2 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on.
7 COMBINATION INSTRUMENT 7.20 Setting kilometers or miles Info Make the country-specific setting. 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 button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h. 401303-01 7.21 Setting the time Condition The ignition is on. The motorcycle is stationary.
7 COMBINATION INSTRUMENT – 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. – Set the hours display using the MODE button. – Set the minutes display using the SET button. – Press the MODE and SET buttons for 5 - 10 seconds. The time is set. 401303-01 7.22 Adjusting the shift speed RPM 1 Condition The ignition is on. The motorcycle is stationary.
7 COMBINATION INSTRUMENT 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. The motorcycle is stationary. – Press the MODE button briefly 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 above which the shift warning light lights up constantly.
8 PREPARING FOR USE 8.1 Advice on first use 56 Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
8 PREPARING FOR USE 57 – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. – Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Get used to handling the motorcycle on a suitable piece of land before 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.
8 PREPARING FOR USE 8.3 Loading the vehicle 58 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.
8 PREPARING FOR USE 59 – 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 distribution 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.) Maximum permissible front axle load 125 kg (276 lb.) Maximum permissible rear axle load 210 kg (463 lb.
9 RIDING INSTRUCTIONS 9.1 Checks and maintenance when preparing for use 60 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. ( – Check the brake fluid level of the front brake. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings. ( – Check the brake system function.
9 RIDING INSTRUCTIONS 9.2 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. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
9 RIDING INSTRUCTIONS 62 – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position . . After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time. – Shift gear to neutral. The green idling speed indicator lamp N lights up.
9 RIDING INSTRUCTIONS 63 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. – Press the button for 3 – 5 seconds. The ABS warning lamp starts flashing; ABS is deactivated. 401685-15 9.3 – Starting off Pull the clutch lever, engage 1st gear, release the clutch lever slowly, and simultaneously open the throttle carefully.
9 RIDING INSTRUCTIONS 64 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. – The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles.
9 RIDING INSTRUCTIONS 65 Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of accidents Lack of roadworthiness. – After a fall, check the vehicle as usual before preparing for use. Note Engine failure Overheating of engine. – If the coolant temperature warning lamp lights up, stop and switch off the engine.
9 RIDING INSTRUCTIONS 9.5 66 – Accelerate only up to a speed suitable for the road surface and weather conditions. Particularly in bends, do not shift, and accelerate very carefully. – To shift down, brake if necessary and close the throttle at the same time. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again. – Switch off the engine if you expect to be standing for a long time.
9 RIDING INSTRUCTIONS 67 Warning Danger of accidents Delayed brake action on salted roads. – 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. – Braking should be appropriate to the driving situation and the road conditions.
9 RIDING INSTRUCTIONS – 68 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. – Adapt your braking to the traffic situation and the road conditions. – When braking, release the throttle and apply the front and rear brakes at the same time.
9 RIDING INSTRUCTIONS 69 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. Always let the vehicle cool first. Note Material damage Damage to or destruction of components due to excessive load. – The side stand is only designed for the weight of the motorcycle. Do no sit on the motorcycle when it is resting on the side stand.
9 RIDING INSTRUCTIONS 70 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. Always let the vehicle cool first. – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 9.
9 RIDING INSTRUCTIONS 71 Note Material damage Premature clogging of the fuel filter. – 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. Warning Environmental hazard Improper handling of fuel is a danger to the environment.
10 SERVICE SCHEDULE 10.1 Additional information 72 Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately. 10.2 Required work Every two years Every year 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.
10 SERVICE SCHEDULE 73 Every two years Every year Every 15,000 km (9,300 mi) Every 7,500 km (4,650 mi) After 1,000 km (620 mi) Check the chain tension. ( p. 85) Check the coolant level in the compensating tank. ( p. 146) Check that the radiator fan is functioning properly. ○ ● ● ● ● ○ ● ● ● ● ○ ● ● ● ● ● ● ● ● ● ● Change the air filter, clean the air filter box. Check the cables for damage and routing without sharp bends. ○ Check the valve clearance.
10 SERVICE SCHEDULE 10.3 Recommended work 74 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. ○ ● ● ● Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and correct routing. ○ ● ● ● Check the antifreeze. ○ ● ● Check the screws and nuts for tightness.
11 TUNING THE CHASSIS 11.1 Adjusting the spring preload of the shock absorber 75 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.
11 TUNING THE CHASSIS 11.2 Adjusting the shift lever 76 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 . Adjust the shift lever by turning shift rod . Nut – – 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 threads must be screwed into the seating. – Check adjusting angle .
11 TUNING THE CHASSIS – Tighten nut 77 , 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.
12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the rear wheel stand 78 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. – Insert the adapter in the rear wheel stand.
12 SERVICE WORK ON THE CHASSIS 79 – 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. – Always place the vehicle on a firm and even surface. Preparatory work – Raise the motorcycle with the rear wheel stand. ( Condition – Remove protection cap L02126-10 . p. 78) .
12 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 Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Main work – Secure the motorcycle against falling over.
12 SERVICE WORK ON THE CHASSIS – Mount protection cap 81 . L02126-10 Finishing work – Take the motorcycle off of the rear wheel stand. ( 12.5 p. 78) Removing the front rider's seat L02118-10 – Insert the ignition key in seat lock – 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. and turn it clockwise.
12 SERVICE WORK ON THE CHASSIS 12.6 Mounting the front rider's seat 82 – Attach recesses on the front rider's seat to the fuel tank, push the front rider's seat forward, and lower at the rear. – Check that the front rider's seat is correctly mounted. Catch engages in the recess. 401921-10 12.7 Removing the passenger seat Preparatory work – Remove the front rider's seat. ( Main work – Remove screw – L02191-10 p. 81) with the washer. Lift and take off the passenger seat.
12 SERVICE WORK ON THE CHASSIS 12.8 Mounting the passenger seat 83 Main work – Position the passenger seat. Both hooks engage in the holders . – Lower the passenger seat and push back. – Mount and tighten screw G01073-10 with the washer. Guideline Screw, passenger seat M6 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.
12 SERVICE WORK ON THE CHASSIS 12.9 Checking for chain dirt accumulation – 84 Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 84) 400678-01 12.10 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.
12 SERVICE WORK ON THE CHASSIS 85 Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 78) 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. 195) After drying, apply chain spray. Chain lube for road use ( p. 195) 400725-01 Finishing work – Take the motorcycle off of the rear wheel stand. ( 12.11 p.
12 SERVICE WORK ON THE CHASSIS 86 – 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. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension » If the chain tension does not meet specifications: – L02128-10 5… 7 mm (0.2… 0.28 in) Adjust the chain tension. ( p.
12 SERVICE WORK ON THE CHASSIS 12.12 Adjusting the chain tension 87 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. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.
12 SERVICE WORK ON THE CHASSIS 88 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) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position in relation to reference marks . The rear wheel is then correctly aligned. Info The upper chain section must be taut.
12 SERVICE WORK ON THE CHASSIS (RC 125) – Loosen nut 89 . . – 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) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position in relation to reference marks . The rear wheel is then correctly aligned. Info The upper chain section must be taut.
12 SERVICE WORK ON THE CHASSIS 12.13 Checking the chain, rear sprocket, and engine sprocket – 90 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.
12 SERVICE WORK ON THE CHASSIS 91 – Shift gear to neutral. – Pull the lower chain section with specified weight . Guideline Weight, chain wear measurement – Measure the distance 15 kg (33 lb.) of 20 chain links in the lower chain section. Info A 0 Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance chain section » B 0 If distance – at the longest 301.6 mm (11.
12 SERVICE WORK ON THE CHASSIS 92 – 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 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 chain sliding guard is loose: – Tighten the chain sliding guard. L02167-10 12.
12 SERVICE WORK ON THE CHASSIS Main work – Pull loop – L02144-10 toward the rear. forward and remove toward the top.
12 SERVICE WORK ON THE CHASSIS 12.15 Mounting the battery cover Main work – Position battery cover 94 and pull toward the rear. The battery cover engages with an audible click. – Check the battery cover is seated correctly. L02141-10 Finishing work – Mount the front rider's seat. ( 12.16 p. 82) Removing the front spoiler Preparatory work – Remove the right side cover. – Remove the left side cover. Main work – Remove screws G01029-10 . ( ( p. 101) p.
12 SERVICE WORK ON THE CHASSIS – Remove screw – Remove screws – Remove screw . G00976-12 . G00977-12 G01721-13 – . Remove screw . – Take off the front spoiler.
12 SERVICE WORK ON THE CHASSIS 12.17 Fitting front spoiler 96 Main work – Position the front spoiler. – Mount and tighten screw . Guideline Screw, front spoiler retaining bracket, rear, on engine – Mount and tighten screw M6 9 Nm (6.6 lbf ft) M6 9 Nm (6.6 lbf ft) M6 6 Nm (4.4 lbf ft) . Guideline G01721-14 Screw, front spoiler retaining bracket, rear, on engine – Mount and tighten screws .
12 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 97 . Guideline Screw, front spoiler, right, on footrest bracket M6 7 Nm (5.2 lbf ft) M6 7 Nm (5.2 lbf ft) G00976-13 – Mount and tighten screws . Guideline Screw, front spoiler G01029-11 Finishing work – Install the left side cover. – Install the right side cover. ( p. 99) ( p.
12 SERVICE WORK ON THE CHASSIS 12.18 Removing the left side cover – 98 – . Remove screws . – Pull off holding lug in area – Remove expanding rivet Remove screws . G00963-10 G00964-10 .
12 SERVICE WORK ON THE CHASSIS – Swing the side cover outward. – Pull hose – Take off the side cover. – Position hose out of hose guide . L02200-10 12.19 Installing the left side cover L02200-11 in hose guide .
12 SERVICE WORK ON THE CHASSIS 100 – Position the side cover. – Mount and tighten screws . Guideline Screw, side cover M6 – Push on the side cover in area – Mount and tighten screws 7 Nm (5.2 lbf ft) . The holding lug engages in the drilled hole on the front spoiler. . Guideline G00963-10 Screw, side cover on front mask – L02198-10 Mount expanding rivet . M6 6 Nm (4.
12 SERVICE WORK ON THE CHASSIS 12.20 Removing the right side cover – 101 – . Remove screws . – Pull off holding lug in area – Remove expanding rivet – Take off the side cover. Remove screws . L02178-10 L02185-10 .
12 SERVICE WORK ON THE CHASSIS 12.21 Installing the right side cover 102 – Position the side cover. – Mount and tighten screws . Guideline Screw, side cover – M6 Push on the side cover in area 7 Nm (5.2 lbf ft) . The holding lug engages in the drilled hole on the front spoiler. – Mount and tighten screws . Guideline L02178-10 Screw, side cover on front mask – L02185-10 Mount expanding rivet . M6 6 Nm (4.
13 BRAKE SYSTEM 13.1 ABS/antilock brake system (RC 125) 103 The ABS unit , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor is located at the front and rear wheels. Warning Danger of accidents Functional limitations of the ABS – The rear wheel may only be spun with the front brake applied (burn out) if the ABS is switched off.
13 BRAKE SYSTEM 104 The ABS warning lamp must light up briefly after the ignition is switched on and should then go out after starting off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays functional; only ABS control is not available.
13 BRAKE SYSTEM 105 – – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc shows signs of damage, cracking, or deformation: – 13.3 Change the brake discs. Change the brake discs. Checking the brake fluid level of the front brake 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.
13 BRAKE SYSTEM 13.4 Adding front brake fluid 106 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. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children.
13 BRAKE SYSTEM 107 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – – – . Remove cover with membrane . Add brake fluid to level . Remove screws Guideline Level L02133-10 Brake fluid DOT 4 / DOT 5.1 ( – 5 mm (0.2 in) p. 192) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 13.
13 BRAKE SYSTEM 108 – Check the brake linings for minimum thickness Minimum thickness » ≥ 1 mm (≥ 0.04 in) If the minimum thickness is less than specified: – – . Change the front brake linings. Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the front brake linings. L02134-10 13.6 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system.
13 BRAKE SYSTEM 109 (RC 200) – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking – Add rear brake fluid. ( : p. 109) L02196-10 (RC 125) – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking – Add rear brake fluid. ( : p. 109) L02136-10 13.7 Adding rear brake fluid Warning Danger of accidents Failure of the brake system.
13 BRAKE SYSTEM 110 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – 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 fluid.
13 BRAKE SYSTEM 111 Main work (RC 200) – Stand the vehicle upright. – – with membrane . Add brake fluid to level . Remove screw cap Brake fluid DOT 4 / DOT 5.1 ( – L02197-10 p. 192) Refit screw cap with membrane. Info Clean up overflowed or spilt brake fluid immediately with water. (RC 125) – Stand the vehicle upright. – Remove screw cap – Add brake fluid to level with membrane . . Brake fluid DOT 4 / DOT 5.1 ( – L02137-10 13.8 p. 192) Refit screw cap with membrane.
13 BRAKE SYSTEM 112 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. – Check the brake linings for minimum thickness Minimum thickness » ≥ 1 mm (≥ 0.04 in) If the minimum thickness is less than specified: – – . Change the rear brake linings.
13 BRAKE SYSTEM 113 – 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 » If the free travel does not meet specifications: – – 3… 5 mm (0.12… 0.2 in) Adjust the free travel of the foot brake lever. Reconnect spring ( p. 113) . L02135-10 13.
13 BRAKE SYSTEM 114 – Disconnect spring – Release nut . and use screw to adjust the specified free travel . Guideline Free travel at foot brake lever Info The range of adjustment is limited. L02135-11 – Hold screw – Attach spring and tighten nut . . 3… 5 mm (0.12… 0.
14 WHEELS, TIRES 14.1 Removing the front wheel 115 Preparatory work – Raise the motorcycle with the rear wheel stand. ( – Raise the motorcycle with the front wheel stand. ( p. 78) p. 79) Main work (RC 200) – Loosen screw – and screws . Unscrew 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.
14 WHEELS, TIRES 116 (RC 125) – Remove screws – – – and push the fender to the side. 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 wheel spindle out of the axle clamp. Remove screw . Remove screw 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.
14 WHEELS, TIRES 117 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 Long-life grease ( and mating surfaces of the spacers. p. 195) – Insert the spacers. – Clean the thread of the wheel spindle and screw – Position the front wheel and insert the wheel spindle. . The brake linings are correctly positioned.
14 WHEELS, TIRES 118 (RC 125) – Remove spacers – » If the wheel bearing is damaged or worn: – – . Check the wheel bearing for damage and wear. Change the front wheel bearing. Clean and grease the shaft seal rings Long-life grease ( L02183-11 and mating surfaces of the spacers. p. 195) – Insert the spacers. – Clean the thread of the wheel spindle and screw – Position the front wheel and insert the wheel spindle. . The brake linings are correctly positioned.
14 WHEELS, TIRES 119 – Tighten screws . Guideline Screw, fork stub M8 Finishing work – Take the motorcycle off of the front wheel stand. ( – 14.3 15 Nm (11.1 lbf ft) p. 80) Take the motorcycle off of the rear wheel stand. ( p. 78) Preparatory work – Raise the motorcycle with the rear wheel stand. ( p.
14 WHEELS, TIRES 120 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. 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 of the swingarm.
14 WHEELS, TIRES 121 (RC 125) – Remove screw – – and pull wheel speed sensor out of the hole. and the washer. Remove chain adjuster . Holding the rear wheel, withdraw wheel spindle with the washer and chain Remove nut adjuster. – 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 in such a way that the brake discs are not damaged.
14 WHEELS, TIRES 122 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. 125) Remove spacers – Check the wheel bearing for damage and wear. » – . If the wheel bearing is damaged or worn: – Change the rear wheel bearing.
14 WHEELS, TIRES 123 – Pull the rear wheel back and mount wheel spindle adjuster . with the washer and chain Info Mount the left and right chain adjusters in the same position. – Mount nut – Push the rear wheel forward so that the chain adjusters are in contact with the screws, and tighten nut . and washer. Guideline 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 .
14 WHEELS, TIRES 124 – 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. – Pull the rear wheel back and mount wheel spindle adjuster . with the washer and chain Info Mount the left and right chain adjusters in the same position.
14 WHEELS, TIRES 14.5 Checking the rear hub rubber dampers 125 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 – Raise the motorcycle with the rear wheel stand. ( – Remove the rear wheel. Main work – Check bearing » . Change the rear wheel bearing. Check the rubber dampers » p.
14 WHEELS, TIRES 126 – Change all rubber dampers in the rear hub. Finishing work – Install the rear wheel. – 14.6 ( p. 121) Take the motorcycle off of the rear wheel stand. ( p. 78) Checking the tire condition Warning 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.
14 WHEELS, TIRES 127 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in objects or other damage: – – Change the tires. Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tires. Check the age of the tires.
14 WHEELS, TIRES 128 – 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 400695-01 » 2.0 bar (29 psi) Rear 2.2 bar (32 psi) If the tire air pressure does not meet specifications: – – Front Correct the tire air pressure. Mount the dust cap.
15 ELECTRICAL SYSTEM 15.1 Removing the battery 129 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. – 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.
15 ELECTRICAL SYSTEM 130 – Pull back the positive terminal cover – Disconnect the positive cable – Detach rubber band – Pull the battery up and out of the battery holder. . of the battery. . Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged. The vehicle is therefore no longer roadworthy. L02157-11 15.2 Installing the battery Main work – Position the battery in the battery holder.
15 ELECTRICAL SYSTEM – – 131 of the battery. Position the negative terminal cover . Connect the negative cable L02156-11 Finishing work – Mount the battery cover. ( 15.3 p. 94) – Mount the front rider's seat. ( – Set the clock. ( p. 82) p. 53) Recharging 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.
15 ELECTRICAL SYSTEM 132 Warning Environmental hazard The battery contains elements that are harmful to the environment. – 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.
15 ELECTRICAL SYSTEM 133 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 battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid – . Switch off the charger after charging. Disconnect the battery. Guideline The charge current, charge voltage and charge time must not be exceeded.
15 ELECTRICAL SYSTEM 15.4 Changing the ABS fuses (RC 125) 134 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. The third fuse, which protects the ABS control unit, is located in the fuse box.
15 ELECTRICAL SYSTEM 135 Fuse (75011088015) ( p. 185) Tip 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. – – L02158-11 Use only fuses with the prescribed amperage. Never bypass or repair fuses. Use spare fuses with the correct rating only. Fuse (90111088025) ( p.
15 ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers 136 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. – Remove the front rider's seat. ( – Remove the battery cover. ( p. 81) p. 92) Main work (RC 200) – Open fuse box cover. – Remove the defective fuse.
15 ELECTRICAL SYSTEM 137 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. Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 185) Fuse (75011088015) ( p. 185) Fuse (75011088030) ( p. 185) Tip Replace the spare fuse in the fuse box so that it is available if needed.
15 ELECTRICAL SYSTEM 138 (RC 125) – Open fuse box cover. – Remove the defective fuse.
15 ELECTRICAL SYSTEM 139 Fuse (75011088010) ( p. 185) Fuse (75011088015) ( p. 185) Fuse (75011088030) ( p. 185) Tip Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the battery cover. ( – 15.6 p. 94) Mount the front rider's seat. ( p. 82) Changing the low beam bulb Note Damage to reflector Reduced brightness.
15 ELECTRICAL SYSTEM 140 Main work – Turn socket – counterclockwise. – 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. Pull the socket with low beam bulb Low beam (H11 / Sockel PGJ19-2) ( p. 185) L02161-10 L02166-10 – Position the socket with the low beam bulb in the headlight housing. – Turn the socket clockwise. – Check that the lighting is functioning properly.
15 ELECTRICAL SYSTEM 15.7 Changing the high beam bulb 141 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. Preparatory work – Switch off all power consumers and switch off the engine. Main work – Turn socket – counterclockwise. – out of the headlight housing. Disconnect the socket with the high beam bulb from connector and remove.
15 ELECTRICAL SYSTEM 142 – 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 A 0 – 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. – Make another mark at a distance under the first mark.
15 ELECTRICAL SYSTEM 143 » If the light-dark border does not meet specifications: – 15.9 Adjust the headlight range of the low beam. ( p. 144) Checking the high beam headlight adjustment 0 A – 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. – Make another mark at a distance under the first mark.
15 ELECTRICAL SYSTEM 15.10 Adjusting the headlight range of the low beam 144 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). Info L02164-10 Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.
16 COOLING SYSTEM 16.1 Cooling system 145 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. This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
16 COOLING SYSTEM 146 The coolant is cooled by the air stream and a radiator fan , which is controlled by a thermoswitch. 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 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.
16 COOLING SYSTEM 147 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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children. Condition The engine is cold.
16 COOLING SYSTEM 16.3 Checking the antifreeze and coolant level 148 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. In case of scalding, rinse immediately with lukewarm water. Warning Danger of poisoning Coolant is poisonous and a health hazard.
16 COOLING SYSTEM 149 » If the coolant level does not meet specifications: – Correct the coolant level. Coolant ( p. 192) – Mount the cap of the compensating tank. – Remove radiator cap – Check the coolant antifreeze. . −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – – Correct the coolant antifreeze. Check the coolant level in the radiator. The radiator must be completely filled.
16 COOLING SYSTEM 16.4 Correcting the coolant level in the compensating tank 150 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. In case of scalding, rinse immediately with lukewarm water. Warning Danger of poisoning Coolant is poisonous and a health hazard.
16 COOLING SYSTEM 16.5 Draining the coolant 151 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. In case of scalding, rinse immediately with lukewarm water. Warning Danger of poisoning Coolant is poisonous and a health hazard.
16 COOLING SYSTEM 152 Guideline 16.6 Plug, water pump drain hole (RC 125) M6 8 Nm (5.9 lbf ft) Plug, water pump drain hole (RC 200) M6 8 Nm (5.9 lbf ft) Filling/bleeding the 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 immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
16 COOLING SYSTEM 153 – Release bleeder screw – 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 ( by three turns. p. 192) – Fill the radiator completely with coolant. Mount the radiator cap. – Rest the vehicle on the side stand. L02265-10 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
16 COOLING SYSTEM 154 – Install the right side cover. ( p.
17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable 155 – 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… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. ( p.
17 TUNING THE ENGINE 17.2 Adjusting the play in the throttle cable 156 – 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 – G01075-10 17.3 3… 5 mm (0.12… 0.2 in) – . Slide on sleeve . – Check the clutch lever for smooth operation. – Move the handlebar to the straight-ahead position.
17 TUNING THE ENGINE 157 » If the clutch lever play changes: – 17.4 Check the routing of the clutch cable. Adjusting the clutch cable play – Move the handlebar to the straight-ahead position. – Push back sleeve – . Loosen lock nut . – Adjust the play in the clutch level by turning adjusting screw . Guideline Clutch lever play L02155-10 – Tighten lock nut – Slide on sleeve . . 1… 3 mm (0.04… 0.
18 SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level 158 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. The engine oil must be between the lower and upper edge of the oil level viewer. » L02201-10 18.2 If the engine oil level is not at the specified level: – Add the engine oil. ( p.
18 SERVICE WORK ON THE ENGINE 159 Info Drain the engine oil only when the engine is warm. Preparatory work – Remove the right side cover. ( p. 101) – Remove the left side cover. ( – Remove the front spoiler. ( p. 94) – Stand the motorcycle on its side stand on a horizontal surface. p. 98) Main work – Place a suitable container under the motor. L02168-10 – Remove the oil drain plug – Remove oil screen – Completely drain the engine oil.
18 SERVICE WORK ON THE ENGINE – – 160 . Remove the oil filter cover with the O-ring. Pull oil filter out of the oil filter housing. Remove screws Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. – Insert oil filter – Lubricate the O-ring of the oil filter cover. Mount the oil filter cover – Mount and tighten the screws. L02169-10 . . Guideline L02170-10 Screw, oil filter cover (RC 125) M5 8 Nm (5.
18 SERVICE WORK ON THE ENGINE – 6 0 Remove the oil filler plug engine oil. Engine oil L02203-10 – 161 with the O-ring from the clutch cover and fill up with 1.5 l (1.6 qt.) Outside temperature: 0… 50 °C (32… 122 °F) Engine oil (SAE 15W/50) ( p. 192) Outside temperature: −10… 40 °C (14… 104 °F) Engine oil (SAE 10W/40) ( p. 193) Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
18 SERVICE WORK ON THE ENGINE Main work – Remove the oil filler plug engine oil. 1 0 162 with the O-ring from the clutch cover and fill up with Engine oil (SAE 15W/50) ( p. 192) Engine oil (SAE 10W/40) ( p. 193) Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. 401955-10 – Install and tighten the oil filler plug with the O-ring.
19 CLEANING, CARE 19.1 Cleaning the motorcycle 163 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 pressure can cause malfunctions or destroy these parts.
19 CLEANING, CARE 164 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. – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system.
19 CLEANING, CARE 165 Perfect Finish and high gloss polish for paints ( p. 196) 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. 196) – Oil the ignition/steering lock. Universal oil spray ( 19.2 p.
19 CLEANING, CARE 166 – 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. – Clean the chain. ( p.
20 STORAGE 20.1 Storage 167 Info If you want to garage the motorcycle for a longer period, take the following steps. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. – When refueling for the last time before taking the motorcycle out of service, add fuel additive.
20 STORAGE 168 – Raise the motorcycle with the front wheel stand. ( – Cover the motorcycle with a tarp or similar cover that is permeable to air. p. 79) Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running 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.
21 TROUBLESHOOTING 169 Faults Possible cause Action Engine does not crank when the electric starter button is pressed Operating error – Go through the steps of starting the engine. ( p. 61) Battery discharged – Recharge the battery. Fuse 1, 3, 4, or 7 is blown – Change the fuses of individual power consumers. ( p. 136) No ground connection present – Check the ground connection. Engine turns only if the clutch lever is drawn The vehicle is in gear – Shift gear to neutral.
21 TROUBLESHOOTING 170 Faults Possible cause Action Engine overheats Defect in radiator fan system – Check the radiator fan system. The engine diagnosis warning lamp (MIL) lights up red Defect in fuel injection system – Read out the fault memory using the KTM diagnostics tool. Lack of fuel – Refuel. ( Fuse 1, 3, 4, or 7 is blown – Change the fuses of individual power consumers. ( p. 136) ABS fuse is blown – Change the ABS fuses.
21 TROUBLESHOOTING 171 Faults Possible cause Action Battery discharged Battery is not being charged by alternator – Check the charging voltage. – Check the open-circuit current. Fuse 7 is blown (RC 125) – Change the fuses of individual power consumers. ( p. 136) – Set the clock. ( – Change the fuses of individual power consumers. ( p. 136) – Set the clock. ( – Check the wiring harness and plug-in connection.
22 FLASH CODE 172 Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - measurement range or power problem Blink code of FI warning lamp (MIL) 06 FI 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 Blink code of FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Error level condition Manif
22 FLASH CODE 173 Blink code of FI warning lamp (MIL) 13 FI 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 of FI warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short Error level condition Fuel tank sensor - circuit fault Fuel tank sensor - short circuit to ground Fuel tank sensor - short circuit to plus Blink code of FI warning lamp (MIL) 15 FI war
22 FLASH CODE 174 Blink code of FI warning lamp (MIL) 17 FI 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 of FI warning lamp (MIL) 18 FI warning lamp (MIL) flashes 1x long, 8x short Error level condition Engine diagnosis warning lamp (MIL) - circuit fault Engine diagnosis warning lamp (MIL) - short circuit to ground Engine diagnosis warnin
22 FLASH CODE 175 Blink code of FI warning lamp (MIL) 22 FI 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 of FI warning lamp (MIL) 23 FI warning lamp (MIL) flashes 2x long, 3x short Error level condition Travel speed sensor - measurement range or power problem Blink code of FI warning lamp (MIL) 24 FI warning lamp (MIL) flashes 2x long, 4x short Er
22 FLASH CODE 176 Blink code of FI warning lamp (MIL) 26 FI 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 of FI warning lamp (MIL) 27 FI warning lamp (MIL) flashes 2x long, 7x short Error level condition Sensor B reference voltage - input signal too low Sensor B reference voltage - input signal too high Blink code of FI warning lamp (MIL) 33 FI warning lamp (MIL) flashe
22 FLASH CODE 177 Blink code of FI warning lamp (MIL) 45 FI 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 of FI warning lamp (MIL) 49 FI warning lamp (MIL) flashes 4x long, 9x short Error level condition Idle control - input signal too low Idle control - input signal too high Idle control - circuit fault
23 TECHNICAL DATA 23.1 Engine 23.1.1 RC 125 178 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) Valve diameter, exhaust 19 mm (0.75 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.
23 TECHNICAL DATA 179 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 BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm (0.
23 TECHNICAL DATA 180 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.
23 TECHNICAL DATA 181 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 M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, engine vent plate M5 7 Nm (5.2 lbf ft) Loctite® 243™ Screw, oil filter cover M5 8 Nm (5.9 lbf ft) – Screw, retaining bracket M5 6 Nm (4.
23 TECHNICAL DATA 182 Screw, locking lever M6 12 Nm (8.9 lbf ft) Loctite® 243™ Screw, oil pump M6 12 Nm (8.9 lbf ft) Loctite® 243™ Screw, retaining bracket, shaft seal ring, clutch cover M6 11 Nm (8.1 lbf ft) Loctite® 243™ Screw, shift drum locating M6 12 Nm (8.9 lbf ft) Loctite® 243™ Screw, starter 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.
23 TECHNICAL DATA 183 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 M12 15 Nm (11.1 lbf ft) – Nut, inner clutch hub M14LH 60 Nm (44.3 lbf ft) Loctite® 243™ Nut, primary gear/timing chain sprocket M14 55 Nm (40.6 lbf ft) Loctite® 243™ Oil drain plug M24x1.5 15 Nm (11.1 lbf ft) – 23.3 Capacities 23.3.1 Engine oil Engine oil 23.3.2 1.
23 TECHNICAL DATA 23.4 Chassis 184 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 brake caliper, floating Suspension travel Front 125 mm (4.92 in) Rear 150 mm (5.91 in) Brake discs - diameter Front 300 mm (11.81 in) Rear 230 mm (9.06 in) Brake discs - wear limit Front 4.5 mm (0.177 in) Rear 3.6 mm (0.
23 TECHNICAL DATA 185 Chain 5/8 x 1/4” (520) O‑ring Steering head angle 66.5° Wheelbase 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.) Maximum permissible rear axle load 210 kg (463 lb.) Maximum permissible overall weight 335 kg (739 lb.) 23.
23 TECHNICAL DATA 186 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 MRF revz C Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 90501000000 Fork WP Suspension Fork length 736 mm (28.98 in) Fork oil 23.8 460 ml (15.55 fl. oz.
23 TECHNICAL DATA 187 Sport 4 clicks Full payload 8 clicks Static sag 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 - 10 Nm (7.4 lbf ft) – Screw, chain guard EJOT PT® K60x30 4 Nm (3 lbf ft) – Remaining nuts, chassis M4 3 Nm (2.2 lbf ft) – Remaining screws, chassis M4 3 Nm (2.2 lbf ft) – Screw, EFI control unit M4 3 Nm (2.2 lbf ft) – Nut, reflector on retaining plate M5 7 Nm (5.
23 TECHNICAL DATA 188 Screw, rollover sensor M5 6 Nm (4.4 lbf 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 10 Nm (7.4 lbf ft) – Nut, license plate bracket M6 8.5 Nm (6.27 lbf ft) – Nut, shift rod M6 10 Nm (7.4 lbf ft) – Nut, shift rod M6LH 10 Nm (7.4 lbf ft) – Nut, tail light M6 7 Nm (5.
23 TECHNICAL DATA Screw, compensating tank 189 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 fender on axle clamp M6 7 Nm (5.2 lbf ft) – Screw, front fender, top side M6 7 Nm (5.2 lbf ft) – Screw, front mask M6 7 Nm (5.2 lbf ft) – Screw, front mask structure on headlight bracket M6 6 Nm (4.
23 TECHNICAL DATA 190 Screw, radiator air inlet, on frame M6 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 unit M6 6 Nm (4.4 lbf ft) – Screw, shift lever linkage M6 11 Nm (8.1 lbf ft) Loctite® 243™ Screw, side cover M6 7 Nm (5.2 lbf ft) – Screw, side cover on front mask M6 6 Nm (4.
23 TECHNICAL DATA 191 Screw, main silencer M8 23 Nm (17 lbf ft) – Screw, passenger footrest bracket M8 20 Nm (14.8 lbf ft) Loctite® 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 lbf ft) Loctite® 204™ Fitting, engine mounting bracket M10 50 Nm (36.9 lbf ft) – Remaining nuts, chassis M10 45 Nm (33.
24 SUBSTANCES 192 Brake fluid DOT 4 / DOT 5.1 Standard/classification – DOT 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® – Brake Fluid DOT 5.1 Coolant Guideline – Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).
24 SUBSTANCES 193 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 – JASO T903 MA ( p. 197) – SAE ( p.
24 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. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
25 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 Motorex® – Moto Clean 195
25 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® – Quick Cleaner Universal oil spray Recommended supplier Motorex® – Joker 440 Synthetic 196
26 STANDARDS 197 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, 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.
INDEX INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Antilock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 198 Brake linings front brake, checking . . . . . . . . . . . .
INDEX 199 average fuel consumption 1/average fuel consumption 2 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . average fuel consumption 2/service menu . . . . . . . . . . . average speed/average fuel consumption 1 menu . . . . . . coolant temperature indicator . . . . . . . . . . . . . . . . . . . . display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . display TRIP F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distance menu 1 TRIP 1 .
INDEX 200 Front rider's seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Front spoiler installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 removing . . . . . . . . . . . . . . . . . .
INDEX 201 Oil screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Right side cover installing . . . . . . . . . . . . . . . . . . . . .
INDEX 202 Steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*3213246en* 3213246en 10/2014 KTM Motorrad AG 5230 Mattighofen/Austria http://www.ktm.
