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12 service work on the chassis

1. Screw main silencer M8 23 Nm 17 Ibf ft Screw passenger footrest bracket M8 20 Nm 14 8 Ibf ft Loctite 2437 Screw rear brake disc M8 30 Nm 22 1 Ibf ft Loctite 243 Screw shift lever M8 17 Nm 12 5 Ibf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 Ibf ft Screw front brake caliper M8x1 30 Nm 22 1 Ibf ft Loctite 2047 Fitting engine mounting bracket M10 50 Nm 36 9 Ibf ft Remaining nuts chassis M10 45 Nm 33 2 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Banjo bolt brake line M10x1 24 Nm 17 7 Ibf ft Fitting shock absorber bottom M10x1 25 50 Nm 36 9 Ibf ft Screw front footrest bracket M10x1 25 50 Nm 36 9 Ibf ft Screw side stand bracket M10x1 25 33 Nm 24 3 Ibf ft Loctite 243 Stud rear sprocket M10x1 25 50 Nm 36 9 Ibf ft Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft Screw top steering head M16x1 5 52 Nm 38 4 Ibf ft Loctite 204 Lambda sensor M18x1 5 15 Nm 11 1 Ibf ft 24 SUBSTANCES 192 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 Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in co
2. o One time interval Periodic interval 10 SERVICE SCHEDULE 10 3 Recommended work 74 Every 7 500 km 4 650 mi After 1 000 km 620 mi Every four years Every year Check the swingarm bearing Check the wheel bearings Grease all moving parts e g side stand hand lever chain and check for smooth operation O Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and correct routing 4 o o e e Check the antifreeze 4 O Check the screws and nuts for tightness 4 o o e e Change the coolant 4 O One time interval Periodic interval 11 TUNING THE CHASSIS 75 11 1 Adjusting the spring preload of the shock absorber 4 Warning A 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 The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability Set the spring preload by turning adjusting ring 1 using the hook wrench from the tool set Guideline Spring preload Comfort 1 click Standard 4 clicks Sport 4 cl
3. 90 Nm 66 4 Ibf ft 12 SERVICE WORK ON THE CHASSIS RC 125 Loosen nut O Loosen nuts O Adjust the chain tension by turning adjusting screws e on the left and right Guideline 89 Chain tension 5 7 mm 0 2 0 28 in Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters o are in the same position in relation to reference marks O The rear wheel is then correctly aligned Info e The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts O Make sure that chain adjusters o are fitted correctly on adjusting screws e Tighten nut Guideline Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft 12 SERVICE WORK ON THE CHASSIS 90 12 13 Checking the chain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set 4 Info The engine sprocket rear sprocket and chain should always be replaced together 12 SERVICE WORK ON THE CHASSIS Shift gear to neutral 91 Pull the lower chain section with specified weight O Guideline Weight chain wear measurement 15 kg 33 Ib Measure the distance o of 20 chain links in the lower c
4. Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors 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 fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a Suitable canister and keep away from children sy Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Lift the cover o of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap 6 CONTROLS 29 Remove the ignition key Warning Fire hazard Fuel is highly flammable poisonous and harmful to your health After closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Close the filler cap Push down the filler cap until the lock engages The seat lock o is located to the left of the seat It can be locked with the ignitio
5. Side stand switch short circuit to plus 22 FLASH CODE 176 Blink code of Fl warning lamp MIL Fi 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 Fl warning lamp MIL EN 27 Fl 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 Fl warning lamp MIL EN 33 Fl warning lamp MIL flashes 3x long 3x short Error level condition Injector circuit fault Injector input signal too low Injector input signal too high Blink code of Fl warning lamp MIL EN 41 Fl warning lamp MIL flashes 4x long 1x short Error level condition Fuel pump relay circuit fault Fuel pump relay input signal too low Fuel pump relay input signal too high 22 FLASH CODE 177 Blink code of Fl warning lamp MIL Fi 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 Fl warning lamp MIL EN 49 Fl warning lamp MIL flashes 4x long 9x short
6. e Info Wear reduces the thickness of the brake disc in area O of the brake disc Brake discs wear limit Front 4 5 mm 0 177 in Rear 3 6 mm 0 142 in Ifthe brake disc thickness is less than the specified value 13 BRAKE SYSTEM 105 Change the brake discs Check the front and rear brake discs for damage cracking and deformation If the brake disc shows signs of damage cracking or deformation Change the brake discs 13 3 Checking the brake fluid level of the front brake Warning Danger of accidents Failure of the brake system Ifthe 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 Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in viewer 6 If the brake fluid is below the MIN marking Add front brake fluid X p 106 L02132 10 13 13 4 BRAKE SYSTEM 106 Adding front brake fluid a A A A Warning Danger of accidents Failure of the brake system Ifthe brake fluid
7. 157 SERVICE WORK ON THE ENGINE M4l 158 18 1 Checking the engine oil level 158 TABLE OF CONTENTS 18 2 Changing the engine oil and oil filter cleaning the oil screen X 18 3 Adding engine Oil e CLEANING GARE 3 32 2 tit rta easet n Hewn ee rs 19 1 Cleaning the motorcycle 19 2 Checks and maintenance steps for winter A epe aa dod pete Me degei nes NILO ei 20 1 Storage nennen 20 2 Preparing for use after storage TROUBLESHOOTING FLASH CODE yi asa saya ii duca did n ye EE de kn dav Za uid TECHNICAE DA TAL kiii Soc ne d na nanan er k y ak A n k 23 1 Engi n6 KAK KK k kK K 23 1 1 RC125 23 1 2 RC 200 23 2 Engine tightening torques sssse 23 3 Capacitan 23 3 1 Engine oil 23 3 2 UODlallEam teri dinan si ases a 23 3 3 23 4 23 5 23 6 23 7 23 8 23 9 Chassis tightening torques ss 24 SUBSTANCES 25 AUXILIARY SUBSTANCES oscinina neina 19 20 21 22 23 1 MEANS OF REPRESENTATION 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 There your
8. 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 cm 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 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mechanically activated Transmission 6 gear claw shifted Transmission ratio 1st gear 12 34 2nd gear 15 31 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 ignit
9. Main work Secure the motorcycle against falling over Remove the front wheel stand 12 SERVICE WORK ON THE CHASSIS 81 Mount protection cap O Finishing work Take the motorcycle off of the rear wheel stand p 78 12 5 Removing the front rider s seat Insert the ignition key in seat lock o and 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 L02118 10 12 SERVICE WORK ON THE CHASSIS 82 126 Mounting the front rider s seat 50 Attach recesses o on the front rider s seat to the fuel tank push the front rider s seat forward and lower at the rear v Catch e engages in the recess Check that the front rider s seat is correctly mounted Preparatory work Remove the front rider s seat 7 p 81 Main work Remove screw 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 v Both hooks o engage in the holders e Lower the passenger seat and push back G01073 10 Mount and tighten screw e with the washer Guideline Screw passenger seat M6 7 Nm 5 2 Ibf ft Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly
10. Remove expanding rivet O 12 SERVICE WORK ON THE CHASSIS 99 VA AN Swing the side cover outward z E Pull hose o out of hose guide O 2 m Take off the side cover gt x Position hose in hose guide 12 SERVICE WORK ON THE CHASSIS 100 Position the side cover Mount and tighten screws e Guideline Screw side cover M6 7 Nm 5 2 Ibf ft Push on the side cover in area O Y The holding lug engages in the drilled hole on the front spoiler Mount and tighten screws O Guideline Screw side cover on front mask M6 6 Nm 4 4 Ibf ft Mount expanding rivet O 12 SERVICE WORK ON THE CHASSIS 101 Remove screws O Remove screws O Pull off holding lug in area O Remove expanding rivet O Take off the side cover 12 SERVICE WORK ON THE CHASSIS 102 Position the side cover Mount and tighten screws O Guideline Screw side cover M6 7 Nm 5 2 Ibf ft Push on the side cover in area O Y The holding lug engages in the drilled hole on the front spoiler Mount and tighten screws Guideline Screw side cover on front mask M6 6 Nm 4 4 Ibf ft Mount expanding rivet 13 BRAKE SYSTEM 103 13 1 ABS antilock brake system RC 125 The ABS unit which consists of a hydraulic unit ABS control unit and return pump is
11. 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 The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position amp Info e If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to position 4 and turning it to position lll To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 9 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 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 vehicl
12. 42 7 8 TRIP display rniran 43 7 9 Coolant temperature indicator 44 TO lnfo diSp ici a 45 7 11 Riding time average speed menu 46 7 12 Average speed average fuel consumption 1 MURDER ELO LET 46 7 13 Average fuel consumption 1 average fuel consumption 2 menu M E 47 7 14 Average fuel consumption 2 service menu 48 7 15 Service range menlU kW ke 49 7 16 Range riding time menu oocccccccncconnncnnnnnnnncncnnnns 50 7 17 Total distance menu ODO u E 51 7 18 Distance menu 1 TRIP 1 KK 51 7 19 Distance menu 2 TRIP 2 HA 52 7 20 Setting kilometers or miles EU 53 7 21 Setting the time issus dete deka B Ek 53 7 22 Adjusting the shift speed RPM 1 54 7 23 Adjusting the shift speed RPM 2 55 8 PREPARING FOR USE kk kk kk k kk k kk k kk k 56 8 1 Advice on first USE ueste kk kk kk 56 8 2 Running in the engine 57 8 3 Loading the vehicle ooocccccccnconcncnocnncononoconcnns 58 9 RIDING INSTRUCTIONS lk kk k 60 9 1 Checks and maintenance when preparing for Ife 60 9 2 Starting eee inten de reme das ca secun ma mb 61 9 3 Starting off 63 9 4 Shifting riding sce lides 63 9 5 Applying the brakes kk 66 10 11 12 9 6 Stopping ParkiNB occcconccccocnncononoconononannnnoncncnons 9 7 Miu 9 8 Acum SERVICE SCHEDULE actos traia e se ERE etae 10 1 Add
13. PA 402174 10 5 SERIAL NUMBERS 21 5 3 Enginemumber 000 The engine number is stamped on the left side of the engine under the engine sprocket 401949 10 The key number 1 can be found on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYCODECARD in a safe KEYCODECARD place 1234 O Kia 402245 10 6 CONTROLS 22 61 luteh lever 00 The clutch lever 1 is fitted on the left side of the handlebar The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever L02112 10 6 CONTROLS 23 The throttle grip is fitted on the right side of the handlebar L02112 11 The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position 6 CONTROLS 24 The light switch is fitted on the left side of the handlebar Possible states z Low beam on Light switch is turned downward In this position the low z beam and tail light are switched on High beam on The light switch is turned upwards In this position the D low beam the high beam and the tail light are switched on The high beam flasher button is fitted on the left side of the handlebar Possible states e High
14. Mount the protection cap Finishing work Mount the battery cover p 94 Mount the front rider s seat p 82 15 ELECTRICAL SYSTEM 136 15 5 Changing the fuses of individual power consumers e 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 p 81 Remove the battery cover p 92 Main work RC 200 Open fuse box cover Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A start auxiliary relay alarm system OPTIONAL Fuse 3 15 A control unit power relay Fuse 4 15 A ignition coil Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 not used Fuse 8 not used Fuse 9 10 A auxiliary equipment Fuse 10 10 A auxiliary equipment 15 ELECTRICAL SYSTEM 137 Info A defective fuse is indicated by a burned out fuse wire 0 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 7501
15. 14 104 F p 193 Lo2203 10 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 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 Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 96 Install the left side cover amp p 99 Install the right side cover amp p 102 Check the engine oil level p 158 18 3 Adding engine oil e Info Too little engine oil or poor quality engine oil results in premature wear to the engine 18 SERVICE WORK ON THE ENGINE 162 Main work Remove the oil filler plug O with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 15W 50 p 192 Engine oil SAE 10W 40 p 193 e Info For optimal performance of the engine oil do not mix different types of engine 401955 10 oil If appropriate change the engine oil Install and tighten the oil filler plug with the O ring Danger A 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 ventila
16. After mounting the passenger seat check that it is locked correctly by pulling up Check that the passenger seat is correctly mounted Finishing work Mount the front rider s seat p 82 12 SERVICE WORK ON THE CHASSIS 12 9 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation lt gt Ifthe 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 Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 84 12 SERVICE WORK ON THE CHASSIS 85 e Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the rear wheel stand p 78 Ll 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 fo
17. ing range The idle speed must not change If the idle speed changes Check the throttle cable routing 17 TUNING THE ENGINE 156 3172 Adjusting the play in the throttle cable j 7 Move the handlebar to the straight ahead position Push back sleeve O Loosen lock nut O Adjust the play in the throttle cable by turning adjusting screw O Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut O 80107510 Slide on sleeve O Check the clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and determine the play in the clutch lever O Clutch lever play 1 3 mm 0 04 0 12 in If the clutch lever play does not meet specifications Adjust the clutch cable play 4 p 157 y me A A AF Note maz Clutch damage If there is no play on the clutch lever the clutch will begin to slip Before operating the motorcycle always check the clutch lever play Move the handlebar to and fro over the entire steering range The clutch lever play must not change 17 TUNING THE ENGINE 157 Ifthe clutch lever play changes Check the routing of the clutch cable Move the handlebar to the straight ahead position Push back sleeve O Loosen lock nut O Adjust the play in
18. Checking the tire air pressure 127 15 16 17 18 5 ELECTRICAL SYSTEM seeeeennen s 129 15 1 Removing the battery amp EE 129 15 2 Installing the battery amp E 130 15 3 Recharging the battery X 131 15 4 Changing the ABS fuses RC 125 134 15 5 Changing the fuses of individual power JIRIN SNN HHHH mm 136 15 6 Changing the low beam bulb 139 15 7 Changing the high beam bulb 141 15 8 Checking the low beam headlight adjustment 142 15 9 Checking the high beam headlight adjustment 143 15 10 Adjusting the headlight range of the low beam 144 15 11 Adjusting the headlight range of the high DOAN cia acti 144 COOLING SYSTEM 4444 kurk kk kk k 145 16 1 Cooling system Ek 145 16 2 Checking the coolant level in the compensating TANK ec 146 16 3 Checking the antifreeze and coolant level 148 16 4 Correcting the coolant level in the compensating tan 150 16 5 Draining the coolant amp 151 16 6 Filling bleeding the cooling system 152 TUNING THE ENGINE kk kk kk kek keke 155 17 1 Checking the play in the throttle cable 155 17 2 Adjusting the play in the throttle cable 156 17 3 Checking the clutch lever play 156 17 4 Adjusting the clutch cable play
19. Ibf ft Rotor screw M10 46 Nm 33 9 Ibf ft Loctite 2437 23 TECHNICAL DATA 183 Screw cylinder head RC 200 M10 Step 1 Thread is oiled head flat is 25 Nm 18 4 Ibf ft greased Step 2 50 Nm 36 9 Ibf ft Water temperature sensor M10 14 Nm 10 3 Ibf ft Spark plug M12 15 Nm 11 1 Ibf ft Nut inner clutch hub M14LH 60 Nm 44 3 Ibf ft Loctite 243 Nut primary gear timing chain sprocket M14 55 Nm 40 6 Ibf ft Loctite 243 Oil drain plug M24x1 5 15 Nm 11 1 Ibf ft 23 3 Capacities 23 3 1 Engine oil Engine oil 1 51 1 6 qt Outside temperature O 50 C Engine oil SAE 15W 50 32 122 F p 192 Outside temperature 10 Engine oil SAE 10W 40 40 C 14 104 F p 193 23 3 2 Coolant Coolant 11 qt Coolant p 192 23 3 3 Fuel Total fuel tank capacity approx 10 2 6 US gal Super unleaded ROZ 95 RON 95 PON 91 p 194 Fuel reserve approx 1 51 1 6 qt 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 Bra
20. Perform a fork service and shock absorber service as needed o e and depending on how the vehicle will be used Clean the dust boots of the fork legs e Check the chain rear sprocket and engine sprocket p 90 10 SERVICE SCHEDULE 73 Every 15 000 km 9 300 mi Every 7 500 km 4 650 mi After 1 000 km 620 mi Every two years Every year Check the chain tension p 85 o e o Check the coolant level in the compensating tank p 146 o Check that the radiator fan is functioning properly o o e e Change the air filter clean the air filter box 4 Check the cables for damage and routing without sharp bends 4 o o e o Check the valve clearance 4 o Check the valve clearance change the spark plugs o Change the front brake fluid amp e Change the rear brake fluid e Check the steering head bearing play o e e Check the low beam headlight adjustment p 142 o Check the high beam headlight adjustment p 143 o Check that the throttle cables are undamaged routed without sharp bends and set correctly 4 o e e e Final check Check the vehicle for roadworthiness and take a test ride o e Read out the fault memory using the KTM diagnostics tool after a test ride 4 O e e Reset the service interval display O e e Make the service entry in KTM Dealer net and in the service record 4 O e e
21. Warning Risk of injury Battery acid and battery gases cause serious chemical burns gt 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 Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician 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 The charge state and the type of charge are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended per
22. and the warning note Low Fuel Level appears on the info display 401293 01 7 COMBINATION INSTRUMENT 44 79 Coolant temperature indicator 000000 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 e Engine cold Up to three bars light up e Engine warm Four to ten bars light up e Engine hot Eleven to thirteen bars light up 401292 01 7 COMBINATION INSTRUMENT 45 Various warning notes appear on info display O If the general warning lamp 9 lights up the corresponding warning note is shown on the info display 401291 10 7 COMBINATION INSTRUMENT 46 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e 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 e Info If the ignition was switched off for over 60 minutes the display is reset to O Press the SET button Next display mode on the info display briefly Condition Alternative 1 The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e The motorcycle is moving Press the SET button brie
23. 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 If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Check the chain tension p 85 Raise the motorcycle with the rear wheel stand p 78 12 SERVICE WORK ON THE CHASSIS Main work RC 200 Loosen nut O Loosen nuts O Adjust the chain tension by turning adjusting screws amp on the left and right Guideline Chain tension 5 7 mm 0 2 0 28 in marks O The rear wheel is then correctly aligned Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters o are in the same position in relation to reference e Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts O Make sure that chain adjusters o are fitted correctly on adjusting screws e Tighten nut Guideline Nut rear wheel spindle M14x1 5
24. depth Minimum tread depth gt 2 mm gt 0 08 in Ifthe tread depth is less than the minimum permissible depth Change the tires Check the age of the tires e Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture KTM recommends that the tires are changed regardless of the actual wear at the latest after 5 years If a tire is more than 5 years old Change the tires e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 14 WHEELS TIRES 400695 01 Remove the dust cap Check tire air pressure when the tires are cold 128 Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap 15 ELECTRICAL SYSTEM 129 gt Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothi
25. express written permission of the copyright owner DEAR KTM CUSTOMER ISO 9001 12 100 6061 FEN According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service 1S0 9001 REG NO 12 100 6061 KTM Motorrad AG 5230 Mattighofen Austria TABLE OF CONTENTS 3 1 MEANS OF REPRESENTATION MA 7 6 CONTRO Sa aida 22 1 1 Symbols Used detecto adas 7 6 1 ClUtCH leve ioi px ee ERR ROS 22 1 2 Formats USE itu baniya bett bay eem mh iuda 7 6 2 Harid brake level ete pis 22 2 SAFETY ADVICE irit da 8 6 3 Throttle grips 31 odio Ml t tp L4 23 2 1 Use GORI IG OM Eda a ite ato er te 8 6 4 Horn butt cni cdit a 23 22 Safety adviCe occcccccncnccconononononnonnncnnnnonononnnnnnononoss 8 6 5 l3ght SWITCH e o Pel i 24 2 3 Degrees of risk and symbols UUUUUUEUUUUULU U 9 6 6 High beam flasher button Ee 24 2 4 Tampering warning esee 9 6 7 Turn signal switch eese 25 2 5 Safe operation tei tc e t eet 10 6 8 Emergency OFF switch K K jK jk i ee 25 2 6 Protective clothing naran aaie a oani 11 6 9 Electric starter DUt O J 26 27 Work MULES a a erate oie 11 6 10 Ignition steering lock 26 2 8 Environment 11 6 1 Locking the steering ens 27 2 9 Owner s Manual ceeee meme 12 6 12 Unlocking the steering E 27 3 IMPORTANT
26. 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 Preparatory work Switch off all power consumers and the engine Remove the front rider s seat p 81 Remove the battery cover p 92 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse O e info A defective fuse is indicated by a burned out fuse wire O 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 15 ELECTRICAL SYSTEM 135 Fuse 75011088015 p 185 e Tip Replace spare fuse o 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 O 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 90111088025 p 185 e Tip Replace spare fuse O in the fuse box so that it is available if needed
27. holder M6 9 Nm 6 6 Ibf ft Screw passenger seat M6 7 Nm 5 2 Ibf ft 23 TECHNICAL DATA 190 Screw radiator air inlet on frame M6 6 Nm 4 4 Ibf ft Screw radiator holder M6 6 Nm 4 4 Ibf ft Screw rear ABS sensor wheel RC 125 M6 6 Nm 4 4 Ibf ft Loctite 204 Screw rear fender M6 7 Nm 5 2 Ibf ft Screw retaining bracket EFI control M6 6 Nm 4 4 Ibf ft unit Screw shift lever linkage M6 11 Nm 8 1 Ibf ft Loctite 243 Screw side cover M6 7 Nm 5 2 Ibf ft Screw side cover on front mask M6 6 Nm 4 4 Ibf ft Screw voltage regulator M6 10 Nm 7 4 Ibf ft Screw voltage regulator holder M6 11 Nm 8 1 Ibf ft Screw wheel speed sensor holder M6 9 Nm 6 6 Ibf ft Loctite 2437 RC 125 Screw windshield M6 9 Nm 6 6 Ibf ft Nut rear sprocket screw M8 27 Nm 19 9 Ibf ft Remaining nuts chassis M8 25 Nm 18 4 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw chain guard M8 11 Nm 8 1 Ibf ft Screw engine bearer on frame M8 24 Nm 17 7 Ibf ft Screw foot brake lever M8 17 Nm 12 5 Ibf ft Loctite 243 Screw front brake disc M8 30 Nm 22 1 Ibf ft Loctite 243 Screw front wheel spindle M8 20 Nm 14 8 Ibf ft Screw fuel tank attachment rear on M8 16 Nm 11 8 Ibf ft frame Screw horn M8 7 Nm 5 2 Ibf ft 23 TECHNICAL DATA 191
28. important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful 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 If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold 3 IMPORTANT NOTES 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 Additional information on the guarantee or warranty and the procedures involved can be found in the Service amp Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manu
29. 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 Wear suitable protective clothing and goggles f 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 Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 107 13 BRAKE SYSTEM 107 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover e with membrane O Add brake fluid to level Guideline Level 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 19
30. motorcycle will be optimally cared for by specially trained experts using the specialist tools required f gt I Indicates a page reference more information is provided on the specified page The typographical formats used in this document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market 2 SAFETY ADVICE 8 24 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad e Info The motorcycle is authorized for public road traffic in the homologous version only A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages e Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 SAFETY ADVICE 2 3 Degrees of risk and symbols 000 Danger Al Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken 1 Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate
31. own safety KTM recommends that you only operate the vehicle while wearing protective clothing Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in parenthe ses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal regulations that per tain to the disposal of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 SAFETY ADVICE 12 29 OwmwrsMamad 000 0 It is
32. slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time If the engine diagnosis warning lamp lights up during a trip stop immediately switch off the engine and contact an authorized KTM workshop Applying the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system Ifthe foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage 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
33. the clutch level O by turning adjusting screw Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut Slide on sleeve hy 18 SERVICE WORK ON THE ENGINE 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 e 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 Ifthe engine oil level is not at the specified level TERET Add the engine oil p 161 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 18 SERVICE WORK ON THE ENGINE 159 e Info Drain the engine oil only when the engine is warm Preparatory work Remove the right side cover 4 9 p 101 Remove the left side cover 4 p 98 Remove the front spoiler p 94 Stand the motorcycle on its side stand on a horizontal surface Main work Place a suitable container under the mot
34. 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 Take the motorcycle off of the front wheel stand p 80 Take the motorcycle off of the rear wheel stand p 78 Recharge the battery 4 p 131 Install the battery 4 p 130 Set the clock p 53 Perform checks and maintenance steps when preparing for use p 60 Take a test ride 21 TROUBLESHOOTING 169 Faults Engine does not crank when the elec tric starter button is pressed Possible cause Operating error Action Go through the steps of starting the engine p 61 Battery discharged Recharge the battery 4 7 p 131 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 The vehicle is in gear and the side stand is folded out Shift gear to neutral Engine turns but does not start Operating error Go through the steps of starting the engine p 61 Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool A Engine has too little power Air filter is very dirty Change the air filter Fuel filter is v
35. the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle L02147 01 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 12 SERVICE WORK ON THE CHASSIS Secure the motorcycle against falling over OAOD 402029 10 12 3 Raising the motorcycle with the front wheel stand Remove the rear wheel stand and lean the vehicle on the side stand O 79 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 p 78 Condition Remove protection cap O 12 SERVICE WORK ON THE CHASSIS L02148 01 Move the handlebar to the straight ahead position Position the wheel stand 80 Adapter 61029955620 Front wheel stand 61029055500 e Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 12 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface L02149 01
36. 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 O Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft RC 125 Check the rear hub rubber dampers 4 p 125 Remove spacers O Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the rear wheel bearing 4 Clean and grease the shaft seal rings 2 and mating surfaces O of the spacers Long life grease p 195 Insert the spacers 14 WHEELS TIRES A L02150 13 124 Clean the thread of the wheel spindle and nut Clean the mating surfaces of the brake caliper support and swingarm Position the rear wheel Y 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 o with the washer and chain adjuster e Info Mount the left and right chain adjusters 5 in the same position Mount nut e and washer Push the rear wheel forward so that the chain adjusters are in contact with the screws and tighten nut O 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 O Nut rear wheel spind
37. 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 O Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the rear brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 4 13 9 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 13 BRAKE SYSTEM 13 Disconnect spring O 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 O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Ifthe free travel does not meet specifications Adjust the free travel of the foot brake lever 4 p 113 Reconnect spring L02135 10 13 10 Adjusting the free travel of the foot brake lever 4 Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on
38. with a discharged battery or without a battery Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds 9 RIDING INSTRUCTIONS 62 OINGO B00782 10 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 O Switch on the ignition by turning the ignition key to the position O Y 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 Y The green idling speed indicator lamp N lights up RC 125 Y The ABS warning lamp lights up and goes back out after starting off Press the electric starter button e Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again Thi
39. workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 111 13 BRAKE SYSTEM L02197 10 L02137 10 111 Main work RC 200 Stand the vehicle upright Remove screw cap o with membrane O Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 192 Refit screw cap with membrane e Info Clean up overflowed or spilt brake fluid immediately with water RC 125 Stand the vehicle upright Remove screw cap o with membrane O Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 192 Refit screw cap with membrane e Info Clean up overflowed or spilt brake fluid immediately with water 13 8 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 13 BRAKE SYSTEM 112 Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in
40. 1088015 p 185 Fuse 75011088030 p 185 e 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 15 ELECTRICAL SYSTEM 138 RC 125 Open fuse box cover Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A start auxiliary relay alarm system OPTIONAL Fuse 3 15 A control unit power relay Fuse 4 15 A ignition coil Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A combination instrument control unit Fuse 8 5 A ABS control unit Fuse 9 10 A auxiliary equipment Fuse 10 10 A auxiliary equipment e Info l 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 75011088005 p 185 15 ELECTRICAL SYSTEM 139 Fuse 75011088010 p 185 Fuse 75011088015 p 185 Fuse 75011088030 p 185 e Tip l Replace the spare fuse in the fuse box so that it is available if needed Check t
41. 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 If the coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Coolant p 192 f you had to add more coolant than the specified amount gt 0 201 gt 0 21 qt Fill bleed the cooling system 4 p 152 Mount the radiator cap Finishing work Install the right side cover 4 p 102 16 COOLING SYSTEM 150 16 4 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Con
42. 2 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe 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 13 BRAKE SYSTEM 108 Check the brake linings for minimum thickness O Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the front brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing Change the front brake linings amp 13 6 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system Ifthe 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 Danger of accidents Reduced braking efficiency due to old brak
43. 50 Cooling system 2 llle 145 filling bleeding i secs e t a dal Ee WW A Wa d BA 152 Customer service kk kk kK KK KK KI KIRI K K eee 14 199 E Electric starter button llle 26 Emergency OFF switch o o o ooooo oo 25 Engine UTI Iri a EA ate ee a 57 Engine number 0 0 00 eee eee ee 21 Engine oil A Bhs hae aa a L dads RUSSE 161 Changing ce lt k te cad A See eee n y k r G 158 Engine oil level CHECKING 4ya s aa Sle a o aia ES 158 Engine sprocket GHECKING zerora RA E SURE REM 90 Environment Aaria A SENS ui REM 11 F dul qme EID nee n amp z 14 Filler cap C IOST 0 6 2 2 x yan a e dad 3b HT SR T ae 29 obpenihg a a A he o Mes e tx 28 Filling up e A Sue E nn 70 Fl sh COd taa kanike A 172 177 Foot brake lever llle 32 free travel adjusting 0 0 KK RIK K KIRI eee 113 free travel checking kk kk kk KK KI KI KI KIRI KI KI eee ee 112 INDEX Front rider s seat MOUNTING sorna a la ii 82 removlng iii a a oe ae ed 81 Front spoiler INStANING oca a a ad 96 FEMOVING aa ds n P NAY eee Gh te ee 94 Front wheel Stalling 551 a kr sa ao a E e C k n ate dak n 116 IMOVINE Sa ols muon ds it da 115 Fuse individual power consumers changing 136 Fuses ABS changilig icu ou em my Pe Reaper 134 Grabhandles 30 Hand brake lever A SK KK KR KK KK KII 22 Headlight range of low b
44. 8 PREPARING FOR USE 57 Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Y You receive a delivery certificate and the service record at vehicle handover 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 Run the engine in p 57 8 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000 km 620 mi 7 500 rpm e Tip l During the running in phase set the shift warning light to the specified engine speed Adjust the shift speed RPM 1 p 54 Adjust the shift speed RPM 2 p 55 Avoid fully opening the throttle 8 8 3 PREPARING FOR USE 58 Loading the vehicle Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of sui
45. 8 Side stand i suce Ah Mase mat ale x den ERO RE As 33 Spare Pants 2G AAA A EAD 13 Starting s o Recte HELL a xe EE S mS s 61 INDEX Steering lOCKIDB raras aladas 27 UNIOCKING iva eel a ne Oe wa de ee es 27 Steering lock cio ia Qi Pi RA ae IESUS 26 StOPPING 03 eave Ga DD ad SAS GR Es E 68 N n A e a str uses E tel 167 Technical data capacities kuya Ka kl hk la ail e oe Wd hn qe a 183 ECT TRECENTIS 184 chassis tightening torques o oooooooooo oo o 187 electrical system llle 185 engine eas cedes HR ae Nath e Ra 178 engine tightening torques eee eee 181 jj Wr Cc 186 Shock absorber lt r cesar ER e aa 2 WA d S 186 TINGS 72 2 et e o AR rito 186 Throttl ri gt lt lt Say rea wal aw n aeg mox W amp 23 Time adjusting xos sehl bs E OR aq la ERA 53 Tire air pressure CHECKING ocn ue aee aaa BNN 127 Tire condition CHECKING vai ae eR eme e E 126 Tool Set iia emer vaa eg d Ed 30 Transport serine may RR EE dt RERO 69 Troubleshooting llli 169 171 202 Turn signal switch llle 25 Type label i4 cia AA a eh es 20 Use definition aaa ees 8 View of vehicle fronbleft icons da a 16 reatcrlglil ca A 18 ME Warranty eI eR aden Aa 13 Winter operation checks and maintenance steps 000 165 Work rules ne bg eet ee eee Oe eee 11 WWW KTM COM 3213246en 10 2014 KTM Motorrad AG 5230 Matt
46. 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 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 immedi ately 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 The radiator is completely full Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank O The coolant level must be between MIN and MAX If there is no coolant in the compensating tank Check the cooling system for leaks 4 e Info Do not start up the motorcycle Fill bleed the cooling system 4 p 152 If the coolant in the compensating tank is not at the required level but the tank is not empty Correct the coolant level in the compensating tank p 150 16 COOLING SYSTEM 148 16 3 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is un
47. 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 19 ol Recommended supplier Motorex Chain Clean Guideline Recommended supplier Motorex Chainlube Road Recommended supplier Motorex Fuel Stabilizer Recommended supplier Motorex Bike Grease 2000 Recommended supplier Motorex Moto Clean 25 AUXILIARY SUBSTANCES 196 Recommended supplier Motorex Moto Polish amp Shine Recommended supplier Motorex Moto Protect Recommended supplier Motorex Quick Cleaner Recommended supplier Motorex Joker 440 Synthetic 26 STANDARDS 197 JASO T903 MA IL Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specification Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos ity The viscosity describes only one property o
48. IRES 126 Change all rubber dampers in the rear hub Finishing work Install the rear wheel 4 p 121 Take the motorcycle off of the rear wheel stand p 78 14 6 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire Inthe interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning A Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning A Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 14 WHEELS TIRES K 400602 10 14 7 Checking the tire air pressure 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 e Info Note local national regulations concerning the minimum tread
49. NOTES ns nat til 13 6 13 Opening the filler cap 28 3 1 Guarantee Warranty A E 13 6 14 Closing the filler cap k l 29 3 2 Operating and auxiliary substances 13 A a A et ed tet ts 29 3 3 Spare parts accessories ooooccccnccononononnononononononos 13 6 16 ToO Sei seti otro dsd 30 SAL Service it oet o e ede estet eo eds 13 6 17 Grab handles tetra ede deter LI eats 30 3 5 Figures ista etur etie 14 6 18 Passenger footrests ly ilham sere oa khal k aiiai 31 3 6 Customet Servic8 rca ridad 14 649 Shift levers to eet bete 31 4 VIEW OE VEHICLE 25 erronee id ita 16 6 20 Foot Drake le Vet ccoeecet rent entes 32 4 1 View of vehicle front left example 16 6 21 Sida dianas 33 4 2 View of vehicle rear right example 18 7 COMBINATION INSTRUMENT eem 34 5 SERIAL NUMBERS oo teet ida 20 7 1 OVBGIV SW C cade dci 34 5 1 Chassistiu rmber u s Lakes tercie la laya ha ka eet ORE S 20 7 2 Activation and T6St ooocccccccnccocnnncncnononnncnnnncnnnone 35 5 2 Type LAD el e piti tr dr o ecu e eet 20 7 3 Warning Tiote5 nay abay te Pe e eet er eta 36 5 3 Engine NUMBER Jc vane hatc pe kaleka dsni 21 7 4 Function DUHONS e re kek leb kik ete ER 39 5 4 Key NUM 3t ao tn e Rt Em as 21 7 5 IndicatorlampS aaa aii 40 7 6 A DD e e eerie rr DD 41 TABLE OF CONTENTS 7 7 Filling level display in fuel tank
50. OWNER S MANUAL 2015 RC 125 EU RC 200 EU RC 200 ASIA RC 200 MY Art no 3213246en 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 We wish you a lot of enjoyment in riding this vehicle Enter the serial numbers of your vehicle below Chassis number p 20 Dealer s stamp Engine number p 21 Key number p 21 The Owner s Manual contained the latest information for this model series at the time of going to print Minor differences due to develop ments in design cannot be ruled out completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices col ors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local condi tions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply O 2014 KTM Motorrad AG Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds is permitted only with the
51. P 1 is always running and counts up to 999 9 Press the SET button Display of TRIP 1 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 2 appears on the display TRIP 2 shows the distance covered since the last reset For example the distance from one refueling stop to the next TRIP 2 is always running and counts up to 999 9 Press the SET button Display of TRIP 2 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton 7 COMBINATION INSTRUMENT 53 e 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 Y The display changes from km h to mph or from mph to km h Condition The ignition is on The motorcycle is stationary 7 COMBINATION INSTRUMENT 54 Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE and SET buttons for 5 10 seconds Y The time display begins to flash Set the hours display using the MODE button Set the minutes display using the SET
52. 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 Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up e Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 84 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Preserving materials for paints metal and rubber p 196 Treat all painted parts with a mild paint polish 19 CLEANING CARE 165 Perfect Finish and high gloss polish for paints p 196 e 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 p
53. al For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are specified in parentheses in the descriptions Your authorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components 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 If you observe these exactly you will ensure a much longer service life for your motorcycle The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembl
54. ar 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 12V 296 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0 8 mm 0 031 in 23 TECHNICAL DATA Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm 0 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 23 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 Ibf ft Loctite 243 Screw engine vent plate M5 7 Nm 5 2 Ibf ft Loctite 243 Screw oil filter cover M5 8 Nm 5 9 Ibf ft Screw retaining bracket M5 6 Nm 4 4 Ibf ft Loctite 243 Screw retaining bracket stator cable M5 8 Nm 5 9 Ibf ft Loctite 243 Screw stator M5 8 Nm 5 9 Ibf ft Loctite 243 Cylinder head screw M6 12 Nm 8 9 Ibf ft Nut water pump impeller M6 10 Nm 7 4 Ibf ft Loctite 2437 Plug water pump drain hole M6 8 Nm 5 9 Ibf ft Screw alternator cover M6 12 Nm 8 9 Ibf ft Screw bearing retainer M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw camshaft bearing bridge M6 11 Nm 8 1 Ibf ft Screw chain securing guide M6 11 Nm 8 1 Ibf ft Loctite 243 Screw clutch cover M6 12 Nm 8 9 Ibf ft Screw engine cas
55. beam flasher button in neutral position e High beam flasher button pressed In this position the headlight flasher high beam is actuated 6 CONTROLS 25 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off a 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 To switch off the turn signal press the turn signal switch towards the switch case The emergency OFF switch o is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is interrupted a running engine stops and a non running engine cannot be started Emergency OFF switch on This position is required for operation the igni tion circuit is closed L02114 10 6 CONTROLS 26 The electric starter button 1 is fitted on the right side of the handlebar 6 9 Electric starter button 5555550 L02114 11 Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated The ignition steering lock is in front of the upper triple clamp Possibl
56. button Press the MODE and SET buttons for 5 10 seconds Y The time is set 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 MODE button for 5 10 seconds Y The display RPM 1 appears e Info The engine speed can be set at intervals of 50 RPM 1 is the engine speed above which the shift warning light starts to flash Set the speed with the MODE and SET buttons e Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds 7 COMBINATION INSTRUMENT 55 Y The display RPM 1 goes out and the set speed is stored 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 Y The display RPM 2 appears e 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 con stantly The speed RPM 2 must always be higher than the speed RPM 1 Set the speed with the MODE and SET buttons e Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds Y The display RPM 2 goes out and the set speed is stored 8 8 1 PREPARING FOR USE 56 Advi
57. ce on first use 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 Always wear protective clothing that is in good condition and meets the legal requirements Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Info When using your vehicle remember that others may feel disturbed by excessive noise
58. der 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 Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If 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 Preparatory work Remove the right side cover X p 101 Main work Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank Q Check the coolant antifreeze 725 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze moo464 10 Check the coolant level in the compensating tank The coolant level must be between MIN and MAX 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 O Check the coolant antifreeze 25 45 C
59. dition The engine is cold The radiator is completely full Preparatory work Check the coolant level in the compensating tank p 146 Main work Remove cover o of the compensating tank Add coolant to the MAX marking Coolant p 192 Mount the cover of the compensating tank M00464 12 16 COOLING SYSTEM 151 16 5 Drainingthe coolant 0 Warning A 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 A Warning ME Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If 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 Preparatory work Remove the right side cover 4 p 101 Remove the left side cover 4 p 98 Remove the front spoiler p 94 Main work Position the motorcycle upright Place a suitable container under the en
60. e M6x40 12 Nm 8 9 Ibf ft Screw engine case M6x60 12 Nm 8 9 Ibf ft Loctite 243 Screw freewheel gear retaining bracket M6 12 Nm 8 9 Ibf ft Loctite 243 23 TECHNICAL DATA 182 Screw locking lever M6 12 Nm 8 9 Ibf ft Loctite 243 Screw oil pump M6 12 Nm 8 9 Ibf ft Loctite 243 Screw retaining bracket shaft seal ring M6 11 Nm 8 1 Ibf ft Loctite 243 clutch cover Screw shift drum locating M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw starter motor M6 12 Nm 8 9 Ibf ft Screw timing chain tensioner M6 12 Nm 8 9 Ibf ft Screw timing chain tensioning rail M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw valve cover M6 12 Nm 8 9 Ibf ft Screw water pump cover M6 12 Nm 8 9 Ibf ft Nut conrod bearing RC 125 M7 24 Nm 17 7 Ibf ft Screw conrod bearing RC 200 M7 24 Nm 17 7 Ibf ft Nut exhaust flange M8 22 Nm 16 2 Ibf ft Screw balancer shaft gear RC 125 M8 25 Nm 18 4 Ibf ft Loctite 2437 Screw balancer shaft gear RC 200 M8 25 Nm 18 4 Ibf ft Loctite 2437 Screw camshaft drive sprocket M8 20 Nm 14 8 Ibf ft Loctite 2437 Screw return spring quick shifter M8 12 Nm 8 9 Ibf ft Loctite 2437 Stud exhaust flange M8 22 Nm 16 2 Ibf ft Cylinder head screw RC 125 M10 Step 1 Thread is oiled head flat is 25 Nm 18 4 Ibf ft greased Step 2 50 Nm 36 9 Ibf ft Oil pressure sensor M10 14 Nm 10 3
61. e fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 13 BRAKE SYSTEM 109 RC 200 Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir Ifthe fluid level reaches the MIN marking O Add rear brake fluid A Y p 109 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 4 p 109 L02136 10 13 7 Adding rear brake fluid a Warning Danger of accidents Failure of the brake system Ifthe 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 13 A A 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 Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM
62. e 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 e info The average fuel consumption 2 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 fuel consumption 2 is reset to O Press the SET button Next display mode on the info display briefly 7 COMBINATION INSTRUMENT 49 SS 5 0 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e 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 e Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range 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 range and riding time is reset to O Press the SET button Next display mode on the info display briefly 7 COMBINATION INSTRUMENT 50 716 Range riding time menu 0000 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ig
63. e states engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Ignition OFF In this position the ignition circuit is interrupted a running Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 6 CONTROLS 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 Y Steering is no longer possible 400732 01 Insert the key into the ignition handlebar lock press in and turn to the right Remove the key Y You can now steer the bike again 400731 01 6 CONTROLS 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
64. e 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 8 Refueling 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 Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors 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 fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel 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 Warnin
65. eam adjusting ata a eee cd ears 144 Headlight range of the high beam adj U SH Ax ria a AAA A 144 High beam bulb changing ani SEN ee hem es Fis gg A 141 High beam flasher button o K3 24 High beam headlight adjustment CHECKING ck xaye a an page RN a fed d d da e 143 200 Hoti button 22a sm awa a h n K ate 23 lenition locK xc teak wa A ad 26 Indicator lamps ALL LV VL VIII ee 40 Key numBer xs a Kek a ate t EE 21 Kilometers or miles adjusting a tl a E 53 Light switeh j 5 dan Alak Y la kan kez ak A data dz ERR an 24 Loading the vehicle sk KK KK KK eee eee 58 Low beam bulb Changing 2a ean gasa pat ita 139 Low beam headlight adjustment CHECKING 4 Si xa ut onda a a RAN AI b gent Cregg as 142 Motorcycle Cleaning e lt cu eS Kl Xal dan dn e Y klr naa ad RH E as 163 raising with the front wheel stand 79 raising with the rear wheel stand o o o 78 taking off of the front wheel stand 80 taking off of the rear wheel stand o 78 Dil filter hanging wend ead Saw RUBER mm e 158 INDEX Oil screen clas a ene 6 a e e 158 Operating substances o o ooo cece eee 13 Owner s Manual LL A LL LAV KK KK KK KI K K K K K K KI K KI KK 12 P Parking y o et to ur tis UE NL dde Ss 68 Passenger footrests AS 0 0 cee ee K K KK 31 Passenger seat MOUNTING s
66. ect the socket with the high beam bulb from connector and remove Connect the new socket with the high beam bulb to the connector High beam H11 Sockel PGJ19 2 p 185 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 15 8 Checking the low beam headlight adjustment b Position the vehicle upright on a horizontal surface in front of a light wall and make a O mark at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle perpendicular to the wall at a distance A from the wall and switch on the low beam 2 Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle 400726 10 Check the low beam headlight adjustment The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable 15 ELECTRICAL SYSTEM 143 Ifthe light dark border does not meet specifications Adjust the headlight range of the low beam p 144 15 9 Checking the high beam headlight adjustment Position the vehicle upri
67. ed or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com 4 4 1 VIEW OF VEHICLE View of vehicle front left example L02145 10 4 VIEW OF VEHICLE Horn button p 23 Light switch p 24 High beam flasher button p 24 Turn signal switch p 25 Clutch lever p 22 Filler cap Seat lock p 29 Side stand p 33 Q OI Bl W IN rR HH Zl Shift lever 7 p 31 4 4 2 VIEW OF VEHICLE View of vehicle rear right example L02146 10 4 VIEW OF VEHICLE 19 Grab handles p 30 Tool set p 30 Ignition steering lock p 26 Emergency OFF switch p 25 Electric starter button p 26 Throttle grip p 23 Hand brake lever p 22 SINIJA A A w N Passenger footrests p 31 Foot brake lever p 32 5 SERIAL NUMBERS 20 The chassis number is stamped on the right side of the frame under the seat 402175 10 The type label is on the right of the frame behind the steering head
68. ee a ates Sieg EE EROR 83 FOMOVING ceo koe dota d r 82 Play in throttle cable AGJUSTING co cc ae Kh ela ee Du EAR ER 156 GheGKING A d bal Sebo Sel u d al 155 Preparing for use advice on first us JA kk kK KK KK KIR K K K KIR ee 56 after storage Ued ia a ar E a Gala lek 168 checks and maintenance when preparing for use 60 Protective clothing o o o oooooooo 11 R Rear hub rubber dampers CHECKING eiri ai cinnan D ae eed eae ae ee ee li 125 Rear sprocket Checking a a eee BLUE ea ex eee ee ees 90 Rear wheel installing a e ce E suh e 121 FEMOVING s ah ceo A be te gus KMN 119 201 Riding uiia eere er UB sei bip Tue 63 Starting OLT o m eue edes dts 63 Right side cover stalling Ben n Ru desea 102 lel canario id e dd ita 101 S Safe operation LL LL KK KK IK KIRI KII KI KIRI eee 10 Seat lok uoo Sr e Ms eth TRE iy 29 A HHH N 13 Service schedule LL LL LL A A KK KI KIR K KIK KIKIKKIKIKIK 72 74 Shift EVO cia it A b koe k y e avay 31 adjusting San E HH HH RS ERI Regno 76 Shift speed RPM 1 AUSTIN idet read awk A N AA UVP el Qey WA 54 Shift speed RPM 2 AUSTIN E o rod ri ad o alk ela ecd 55 SHINE us opu o Ade denn E A aya ke de dal dain a a eben 63 Shock absorber spring preload adjusting sees 75 Side cover left Installing se a teen a Wee ANA ytd a hades ERE ache ata 99 rEMOVINS sar rar ak star Gide edente Seay KARAN E 9
69. eel stand p 80 Take the motorcycle off of the rear wheel stand p 78 Preparatory work Raise the motorcycle with the rear wheel stand p 78 14 WHEELS TIRES 120 Main work RC 200 Remove nut o and the washer Remove chain adjuster O Holding the rear wheel withdraw wheel spindle e with the washer and chain adjuster O 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 e Info Do not operate the foot brake when the rear wheel is removed 14 WHEELS TIRES 121 RC 125 Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove nut e and the washer Remove chain adjuster O Holding the rear wheel withdraw wheel spindle 00 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 e info Do not operate the foot brake when the rear wheel is removed Warning Danger
70. ery dirty Check the fuel pressure Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level in the compensating tank p 146 Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant amp p 151 Fill bleed the cooling system 4 p 152 Thermostat defective Check the thermostat Fuse 5 blown Change the fuses of individual power consumers p 136 21 TROUBLESHOOTING 170 Faults Engine overheats Possible cause Defect in radiator fan system Action Check the radiator fan system 4 The engine diagnosis warning lamp MIL lights up red Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool 4 Engine dies during the trip Lack of fuel Refuel p 70 Fuse 1 3 4 or 7 is blown Change the fuses of individual power consumers p 136 The ABS warning lamp lights up RC 125 ABS fuse is blown Change the ABS fuses p 134 Large difference in wheel speeds of the front and rear wheels Stop the vehicle switch off the ignition and start it again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Eng
71. f oil and says nothing about quality A ABS A A os a we REN ee cdl 103 ACCESSOMNCS 3 3 5 55 merces ta a eA Ge Ree TR e PR 13 Antifreeze CHECKING k roaster ines E e mea Waleed RE ae 148 Antilock brake system o o oooooooo 103 Auxiliary substances KV KIR KK KI eee 13 B Baosage ios ai b al na salla hal GEH a fa 58 Battery installing um ede ne mtn aub tuia nOn 130 recharging a coss d edP n d Win idee 131 FEMOVING s sets dut so tiat Roe ENTE poe Bi Den ER 129 Battery cover MOUNTING sure Sih od an HHHH ae HH HH e s 94 FEMOVING dat E Ee oed t e ae dD n SR 92 Brake discs CHECKING to s A edet ee od rane Bhat sete 104 Brake fluid front brake adding llle 106 rear brake adding XX kk KK KIRI K K K KII KK 109 Brake fluid level front brake checking o o o ooooooooooooo 105 rear brake checking 0 0 00 cece eee ee eee 108 198 Brake linings front brake checking llle 107 rear brake checking cee eee eee eee 111 Brakes tii UE xev dara cure doa MHN M 66 Brakes applying o o ooo ooooooon o o 66 C Capacity coolant xui w pe eei P Eas 183 engine oll uidere wean bal Ete n ps 161 183 DIM P 71 183 Chain chain dirt accumulation checking 84 CHECKING ae gta aci wel IPAE dr RR RR ata 90 Cleaning 12 6 w ree Rc e Ie A eer ers 84 Chain tension adjusting vp a uie mea eo xou CS R
72. fly and repeatedly until the desired info display appears 7 COMBINATION INSTRUMENT 41 In this menu the average speed and the average fuel consumption 1 are displayed in L 100 km or L 100 miles e 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 O Press the SET button Next display mode on the info display briefly Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the aver age fuel consumption 2 in km L or miles L are displayed e Info The average fuel consumptions 1 and 2 are 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 fuel consumption 1 and 2 is reset to O 7 COMBINATION INSTRUMENT 48 Press the SET button Next display mode on the info display briefly Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycl
73. 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 39 You can change the display mode with the MODE button O Possible display modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 8h Pressing and holding the SET button e resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button e changes the info display to the next display mode RC 125 The ABS can be switched off using button 6 RC 200 Button amp has no function 401685 12 7 COMBINATION INSTRUMENT 40 75 Indicatortamps 00000 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 on board 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 The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system OPTIONAL The general warni
74. g Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off the engine Open the filler cap p 28 Fill the fuel tank with fuel up to the lower edge o of the fuel filler Total fuel tank 10 2 6 US gal Super unleaded ROZ 95 RON 95 PON capacity approx 91 p 194 Close the filler cap p 29 10 SERVICE SCHEDULE 72 10 1 Additional information Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced sepa rately 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 Check the functioning of the electrical equipment O e e Change the engine oil and oil filter clean the oil screen 4 p 158 EM B ES Check the brake discs p 104 O e e e Check the front brake linings p 107 O e e e e Check the rear brake linings p 111 o e Check the tire condition p 126 O e e e o Check the tire air pressure p 127 o e e e e Check the brake lines for damage and leakage O e e e e Check the brake fluid level of the front brake p 105 O e Check the rear brake fluid level p 108 o e e Check the shock absorber and fork for leaks
75. ght 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 B under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at a distance O in front of the wall and switch on the high beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the high beam headlight adjustment The center of the light cone must lie exactly on the lower mark when the motorcycle B is ready to operate with the rider mounted along with any luggage and a passenger if i applicable Ifthe center of the light cone is not located where specified Adjust the headlight range of the high beam p 144 400575 10 15 ELECTRICAL SYSTEM 144 15 10 il the headlight range of the low beam Main work Adjust the beam range of the low beam by turning screw O 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 e Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range Finishing work Check the low beam headlight adjustment p 142 15 11 Adju
76. gine Remove screw O Remove the radiator cap Completely drain the coolant Mount and tighten screw with a new seal ring L02173 10 16 COOLING SYSTEM 152 Guideline Plug water pump drain hole RC 125 M6 8 Nm 5 9 Ibf ft Plug water pump drain hole RC 200 M6 8 Nm 5 9 Ibf ft 16 6 Filling bleeding the cooling system A Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children p Main work 4 Remove radiator cap O L02266 10 16 COOLING SYSTEM 153 Release bleeder screw O by three turns Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the bleeder screw and then mount and tighten the bleeder screw immediately Coolant p 192 Fill the radiator completely with coolant Mount the radiator cap Rest the vehicle on the side stand 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 suff
77. gnal too low Intake air temperature sensor input signal too high Blink code of Fl warning lamp MIL EN 14 Fl 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 Fl warning lamp MIL EN 15 Fl warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor plausibility Rollover sensor circuit fault Rollover sensor short circuit to ground Rollover sensor short circuit to plus Blink code of Fl warning lamp MIL EN 16 Fl warning lamp MIL flashes 1x long 6x short Error level condition Radiator fan motor circuit fault Radiator fan motor input signal too low Radiator fan motor input signal too high 22 FLASH CODE 174 Blink code of Fl warning lamp MIL EN 17 Fl 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 Fl warning lamp MIL EN 18 Fl 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 d
78. hain section 18 19 20 401288 10 e Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance o at the longest chain section 301 6 mm 11 874 in f distance e is greater than the specified measurement Change the power set Info e When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets 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 Ifthe chain sliding guard has lost material due to wear to the extent that in area O the drilled hole of screw 1 is visible from above Change the chain sliding guard 4 Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard E E LO2167 10 Preparatory work Remove the front rider s seat p 81 12 SERVICE WORK ON gt e L02144 10 THE CHASSIS Main work Pull loop 1 toward the rear Pull battery cover e forward and remove toward the top 93 12 SERVICE WORK ON THE CHASSIS 94 Main work Position battery cover e and pull toward the rear Y The battery cover engages with an audible click Check the battery cover is seated correctly Finish
79. hat the power consumer is functioning properly Close the fuse box cover Finishing work Mount the battery cover p 94 Mount the front rider s seat p 82 15 6 Changing the low beam bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine 15 ELECTRICAL SYSTEM 140 Main work Turn socket 1 counterclockwise Pull the socket with low beam bulb 2 out of the headlight housing Disconnect the socket with the low beam bulb from connector e and remove Connect the new socket with the low beam bulb to the connector Low beam H11 Sockel PGJ19 2 p 185 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 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 Pull the socket with high beam bulb 2 out of the headlight housing Disconn
80. he condition of the vehicle and ensure that it is roadworthy The vehicle must be in perfect technical condition when used Check the engine oil level p 158 Check the brake fluid level of the front brake p 105 Check the rear brake fluid level 7 p 108 Check the front brake linings p 107 Check the rear brake linings p 111 Check the brake system function Check the coolant level in the compensating tank p 146 Check for chain dirt accumulation p 84 Check the chain tension p 85 Check the tire condition p 126 Check the tire air pressure p 127 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the electrical equipment Check that baggage is correctly secured Sit on the motorcycle and check the rear mirror setting Check the fuel level 9 RIDING INSTRUCTIONS 61 9 2 Starting Danger Al 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 Never operate the vehicle
81. iagnosis warning lamp MIL short circuit to plus Blink code of Fl warning lamp MIL EN 19 Fl warning lamp MIL flashes 1x long 9x short Error level condition Fuel pump lamp circuit fault Low fuel warning lamp input signal too low Low fuel warning lamp input signal too high Blink code of Fl warning lamp MIL EN 21 Fl warning lamp MIL flashes 2x long 1x short Error level condition Engine control relay switch off delay 22 FLASH CODE 175 Blink code of Fl warning lamp MIL Fi 22 Fl 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 Fl warning lamp MIL EN 23 Fl warning lamp MIL flashes 2x long 3x short Error level condition Travel speed sensor measurement range or power problem Blink code of Fl warning lamp MIL EN 24 Fl warning lamp MIL flashes 2x long 4x short Error level condition System voltage too low System voltage too high System voltage implausible value Blink code of Fl warning lamp MIL EN 25 Fl warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch plausibility Side stand switch circuit fault Side stand switch short circuit to ground
82. icient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run warm Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank e and add coolant until the coolant level is up to the MAX mark Mount the cap of the compensating tank Finishing work Fit the front spoiler p 96 Install the left side cover 4 p 99 16 COOLING SYSTEM Install the right side cover 4 p 102 154 17 TUNING THE ENGINE 155 400192 11 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 O in the throttle cable Throttle cable play 3 5 mm 0 12 0 2 in Ifthe throttle cable play does not meet specifications Adjust the play in the throttle cable 4 p 156 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 Start the engine and let it run idle Move the handlebar to and fro over the entire steer
83. icks Full payload 8 clicks L02186 10 Hook wrench shock absorber 90529077000 e Info The spring preload can be set to 10 different positions 11 TUNING THE CHASSIS 76 11 2 Adjusting the shift lever e Info The adjustment range of the shift lever is limited Loosen nut O holding the threaded rod O e Info Nut has a left handed thread Loosen nut e holding the threaded rod e Adjust the shift lever by turning shift rod O Guideline Shift rod adjustment range 150 162 mm 5 91 6 38 in e Info Make the same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle O Guideline Adjusting angle shift rod linkage 75 shift lever L02125 10 Tighten nut 6 holding the threaded rod Guideline Nut shift rod M6 10 Nm 7 4 Ibf ft 11 TUNING THE CHASSIS Tighten nut O holding the threaded rod O Guideline 71 Nut shift rod M6LH 10 Nm 7 4 Ibf ft Check the shift lever to ensure it is functioning properly and can move freely 12 SERVICE WORK ON THE CHASSIS 78 12 1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Mount the supports of the wheel stand Insert the adapter in
84. ighofen Austria http www ktm com Gor Ef REGNO 13 1006061 Photo Mitterbauer KTM
85. 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 The feet must be positioned on the passenger footrests Note the regulations governing the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in 9 RIDING INSTRUCTIONS Warning 65 Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of accidents Lack of roadwor
86. ine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 158 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen 4 p 158 Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers functioning p 136 Turn signal brake light and horn are Fuse 6 blown Change the fuses of individual power consumers not functional p 136 Time is not correctly displayed Fuse 7 is blown RC 125 Change the fuses of individual power consumers p 136 Set the clock p 53 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery 4 7 p 131 21 TROUBLESHOOTING 171 Faults Battery discharged Possible cause Action Battery is not being charged by alter nator Check the charging voltage 4 Check the open circuit current 4 The combination instrument shows nothing on the display Fuse 7 is blown RC 125 Change the fuses of individual power consumers 7 p 136 Set the clock p 53 Fuse 2 blown RC 200 Change the fuses of individual power consumers 7 p 136 Set the clock 7 p 53 Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or plug in c
87. ing work Mount the front rider s seat p 82 Preparatory work Remove the right side cover 4 p 101 Remove the left side cover 4 p 98 EUER Main work Remove screws O G01029 10 12 SERVICE WORK ON THE CHASSIS 95 G00977 12 G01721 13 Remove screw e Remove screws O Remove screw O Remove screw O Take off the front spoiler 12 SERVICE WORK ON THE CHASSIS 96 Main work Position the front spoiler Mount and tighten screw Guideline Screw front spoiler retaining bracket M6 9 Nm 6 6 Ibf ft rear on engine Mount and tighten screw Guideline Screw front spoiler retaining bracket M6 9 Nm 6 6 Ibf ft rear on engine G01721 14 Mount and tighten screws Guideline Screw front spoiler retaining bracket M6 6 Nm 4 4 Ibf ft rear G00977 13 12 SERVICE WORK ON THE CHASSIS Mount and tighten screw O Guideline 97 Screw front spoiler right on footrest M6 bracket 7 Nm 5 2 Ibf ft Mount and tighten screws O Guideline Screw front spoiler M6 7 Nm 5 2 Ibf ft Finishing work Install the left side cover 4 p 99 Install the right side cover 4 p 102 12 SERVICE WORK ON THE CHASSIS 98 G00964 10 Remove screws O Remove screws O Pull off holding lug in area O
88. 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 Ifthe vehicle has been modified such as shortened or lengthened spring deflec tions different rim diameters different tires the wrong tire air pressure differ ent brake linings etc the ABS will not function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires that have been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces Warning Danger of accidents Vehicle rollover Itis not always possible to prevent vehicle rollover in extreme riding situations e g luggage loaded with a high center of gravity varying road surfaces steep descents full braking without disengaging the gear Adapt your riding style to the road conditions and your riding ability The ABS operates with two independent brake circuits front and rear brakes During nor mal operation the brake system operates like a conventional brake system without ABS When the ABS control unit detects the
89. iod it will become over discharged and sulfate destroying the battery The battery is maintenance free which means that the acid level does not need to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the front rider s seat p 81 Remove the battery cover p 92 Disconnect the negative cable of the battery to avoid damage to the motorcycle s elec tronics 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 bat tery and to test the alternator With this device you cannot overcharge the battery e 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 Charge the battery regularly when the 3 months motorcycle is not in use HI E uw L02139 10 Finishing work Mount the battery cover p 94 Mount the front rider s seat 7 p 82 Set the clock p 53 15 ELECTRICAL SYSTEM 134 15 4 Changing the ABS fuses RC 125 0 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
90. ion 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 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 23 1 2 RC 200 Design 1 cylinder 4 stroke engine water cooled Displacement 200 cm 12 2 cu in Stroke 49 mm 1 93 in Bore 72 mm 2 83 in Compression ratio 11 5 1 Control DOHC 4 valves controlled via cam lever chain drive Valve diameter intake 28 5 mm 1 122 in 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 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mechanically activated Transmission 6 gear claw shifted Transmission ratio 1st gear 12 34 2nd gear 15 31 3rd gear 18 28 4th ge
91. iple M6 7 Nm 5 2 Ibf ft Loctite 243 clamp Screw cable holder side stand switch M6 9 Nm 6 6 Ibf ft Loctite 243 Screw chain guard M6 7 Nm 5 2 Ibf ft Screw chain sliding guard M6 7 Nm 5 2 Ibf ft 23 TECHNICAL DATA 189 Screw compensating tank M6 9 Nm 6 6 Ibf ft Screw engine sprocket cover on frame M6 7 Nm 5 2 Ibf ft Screw foot brake cylinder M6 9 Nm 6 6 Ibf ft Loctite 2437 Screw footrest bracket M6 7 Nm 5 2 Ibf ft Screw front fender on axle clamp M6 7 Nm 5 2 Ibf ft Screw front fender top side M6 7 Nm 5 2 Ibf ft Screw front mask M6 7 Nm 5 2 Ibf ft Screw front mask structure on headlight M6 6 Nm 4 4 Ibf ft bracket Screw front seat fixing M6 6 Nm 4 4 Ibf ft Screw front spoiler M6 7 Nm 5 2 Ibf ft Screw front spoiler retaining bracket M6 6 Nm 4 4 Ibf ft rear Screw front spoiler retaining bracket M6 9 Nm 6 6 Ibf ft rear on engine Screw front spoiler right on footrest M6 7 Nm 5 2 Ibf ft bracket Screw ground cable on frame M6 7 Nm 5 2 Ibf ft Screw handlebar stub M6 7 Nm 5 2 Ibf ft Loctite 243 Screw ignition coil M6 9 Nm 6 6 Ibf ft Screw ignition lock M6 11 Nm 8 1 Ibf ft Screw license plate holder on license M6 7 Nm 5 2 Ibf ft plate bracket Screw magnetic holder on side stand M6 4 Nm 3 Ibf ft Loctite 2437 Screw mirror
92. itional information 10 2 Required work c ooccnccccnccoccnccononcnncnononnnnonenonnnnns 10 3 Recommended Work kk TUNING THE CHASSIS o resto earth corran 11 1 Adjusting the spring preload of the shock absorber SN PMC 11 2 Adjusting the shift lever SERVICE WORK ON THE CHASSIS sse 12 1 Raising the motorcycle with the rear wheel ico ERIT EC 12 2 Taking the motorcycle off of the rear wheel Sal E 12 3 Raising the motorcycle with the front wheel Cice ETE 12 4 Taking the motorcycle off of the front wheel stana is conste ern ac eel tote be rtis 12 5 Removing the front rider s seat 12 6 Mounting the front rider s seat 12 7 Removing the passenger seat sssss 12 8 Mounting the passenger seat ss 12 9 Checking for chain dirt accumulation 12 10 Cleaning the chain Ah h k h EE 12 11 Checking the chain tension U 12 12 Adjusting the chain tension 12 13 Checking the chain rear sprocket and engine cele M T TABLE OF CONTENTS 13 14 12 14 Removing the battery cover occcccccccccccccoccncconcnns 92 12 15 Mounting the battery cover seseeeeees 94 12 16 Removing the front spoiler eeesses 94 12 17 Fitting front spoiler ccconccccocncccncncnonnncnccnconin
93. ke 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 0 142 in Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary ratio RC 125 14 45 Secondary ratio RC 200 14 42 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 Ib Weight without fuel approx RC 200 141 5 kg 312 Ib Maximum permissible front axle load 125 kg 276 Ib Maximum permissible rear axle load 210 kg 463 Ib Maximum permissible overall weight 335 kg 739 Ib 23 5 Electrical system Battery ETZ 9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse RC 125 75011088005 5A Fuse 75011088010 10A Fuse 75011088015 15A Fuse 90111088025 25A Fuse 75011088030 30A Low beam H11 Sockel PGJ19 2 12V 55 W High beam H11 Sockel PGJ19 2 12 V 55 W Parking light LED 23 TECHNICAL DATA Instrument lights and indicator lamp
94. le M14x1 5 90 Nm 66 4 Ibf ft Position wheel speed sensor Q in the drill hole Mount and tighten screw O Guideline Screw wheel speed sensor M6 9 Nm Loctite 243 holder 6 6 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 78 14 WHEELS TIRES 125 14 5 Checking the rear hub rubber dampers amp e 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 p 78 Remove the rear wheel 4 p 119 Main work Check bearing O If the bearing is damaged or worn Change the rear wheel bearing 4 Check the rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play O hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm lt 0 2 in f play O is larger than the specified value 14 WHEELS T
95. measures are not taken Caution 4A Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning xt Indicates a danger that will lead to environmental damage if the appropriate measures are not taken Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 2 SAFETY ADVICE 10 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 manufac turer 2 5 Safe operation Danger Al Danger of accidents Danger arising from the rider s judgement bei
96. n key L02118 10 6 CONTROLS 30 618 E I The tool set is in the storage compartment under the seat ad The grab handles 1 are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip L02119 10 6 CONTROLS 31 The passenger footrests can be folded in and out Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger L02120 10 Shift lever o is mounted on the left side of the engine 401950 10 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 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 402177 10 6 CONTROLS 33 The side stand O is on the left side of the vehicle The side stand is used to park the motorcycle e Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions N O Possible states e Side stand folded out The vehicle can be leaned on the side stand The safety start system is active e Side stand folded in This position is mandatory for all trips The safety s
97. ng 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 If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Remove the front rider s seat p 81 Remove the battery cover p 92 Main work Pull back the negative terminal cover O Disconnect the negative cable 2 of the battery 15 ELECTRICAL SYSTEM 130 Pull back the positive terminal cover e Disconnect the positive cable o of the battery Detach rubber band O Pull the battery up and out of the battery holder e 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 vehi cle is therefore no longer roadworthy Main work Position the battery in the battery holder e Info The battery terminals must be at the top Attach rubber band Reconnect the positive cable of the battery Position positive terminal cover e 15 ELECTRICAL SYSTEM 131 Connect the negative cable o of the battery Position the negative terminal cover O Finishing work Mount the battery cover p 94 Mount the front rider s seat p 82 Set the clock p 53
98. ng impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Danger Al 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 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Only operate the vehicle when it is in perfect technical condition in accordance with ts intended use and in a safe and environmentally compatible manner An appropriate driver s license is needed to ride the vehicle on public roads Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop Adhere to the information and warning labels on the vehicle 2 SAFETY ADVICE 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
99. ng lamp lights up yellow An operating safety warning message was detected This is also shown in the info display 90 034 G zo e _ PENN OJE ABS warning lamp lights up flashes yellow Status or error messages relating to ABS antilock brake system 401686 01 7 COMBINATION INSTRUMENT 41 401685 11 The speed 1 is shown in kilometers per hour km h or in miles per hour mph The tachometer 2 shows the engine speed in revolutions per minute The gear display shows the engaged gear The coolant temperature appears in segment O The time appears in segment O The filling level in the fuel tank is displaced in segment O The info display shows additional information e Info After reconnecting the battery or changing the fuse the time must be reset The intensity of the LED display depends on the ambient brightness 7 COMBINATION INSTRUMENT 42 7 1 Filling level display in fuel tank The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank 401292 01 7 COMBINATION INSTRUMENT 43 78 TRIP F display 0 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 e Info At the same time as the display mode TRIP F the general warning lamp Y lights up
100. ng steps Before storing the motorcycle check all parts for function and wear lf 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 aN Fuel additive p 195 Refuel p 70 gt E Clean the motorcycle p 163 Change the engine oil and oil filter clean the oil screen X p 158 Check the antifreeze and coolant level 7 p 148 401058 01 Check the tire air pressure p 127 Remove the battery 4 p 129 Recharge the battery 4 p 131 Guideline Storage temperature of battery without 0 35 C 32 95 F direct sunlight Store the vehicle in a dry location that is not subject to large fluctuations in tempera ture e Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rear wheel stand p 78 20 STORAGE 20 2 Preparing for use after storage 2 N 401059 01 168 Raise the motorcycle with the front wheel stand p 79 Cover the motorcycle with a tarp or similar cover that is permeable to air Info e Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running
101. nition is on e 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 e Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range 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 range and riding time is reset to O Press the SET button Next display mode on the info display briefly 7 COMBINATION INSTRUMENT 51 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until ODO appears on the display ODO shows the total distance covered e Info This value is retained even if the battery is disconnected and or the fuse blows Press the MODE but Next display mode on the display ton Condition Alternative 1 The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 1 appears on the display 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 TRI
102. nns 96 12 18 Removing the left side cover A 98 12 19 Installing the left side cover 3 99 12 20 Removing the right side cover A 101 12 21 Installing the right side cover X 102 BRAKE SYSTEM scsi 103 13 1 ABS antilock brake system RC 125 103 13 2 Checking the brake discs eessessse 104 13 3 Checking the brake fluid level of the front o 105 13 4 Adding front brake fluid XJ 106 13 5 Checking the front brake linings 107 13 6 Checking the rear brake fluid level 108 13 7 Adding rear brake fluid ssessessssssss 109 13 8 Checking the rear brake linings 111 13 9 Checking the free travel of foot brake lever 112 13 10 Adjusting the free travel of the foot brake le CIL 113 WHEELS TIRES asocia va seti eee xor da daci n 115 14 1 Removing the front wheel EUUUUEEUUUULULU 115 14 2 Installing the front wheel 116 14 3 Removing the rear wheel 4 ssssssss 119 14 4 Installing the rear wheel X UU U UL L U E jEU 121 14 5 Checking the rear hub rubber dampers 4 125 14 6 Checking the tire condition 126 14 7
103. of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 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 4 p 125 Remove spacers O Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the rear wheel bearing 4 Clean and grease the shaft seal rings 12 and mating surfaces A of the spacers Long life grease p 195 Insert the spacers Clean the thread of the wheel spindle and nut e Clean the mating surfaces of the brake caliper support and swingarm Position the rear wheel Y The brake linings are correctly positioned Push the rear wheel as far forward as possible and place the chain on the rear sprocket 14 WHEELS TIRES L02151 11 123 Pull the rear wheel back and mount wheel spindle o with the washer and chain adjuster e Info Mount the left and right chain adjusters o in the same position Mount nut e and washer Push the rear wheel forward so that the chain adjusters are in contact with the screws and tighten nut O Guideline In order for
104. onnection is oxidized Check the wiring harness and plug in connection 22 FLASH CODE 172 Blink code of Fl warning lamp MIL a 02 FI warning lamp MIL flashes 2x short Error level condition Crankshaft position sensor measurement range or power problem Blink code of Fl warning lamp MIL e 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 Fl warning lamp MIL D 09 FI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor input signal too low Manifold absolute pressure sensor input signal too high Blink code of FI warning lamp MIL D 11 FI warning lamp MIL flashes 1x long 1x short Error level condition Idle control engine speed below target value Idle control engine speed above target value Blink code of Fl warning lamp MIL D 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high 22 FLASH CODE 173 Blink code of Fl warning lamp MIL EN 13 Fl warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input si
105. or Remove the oil drain plug 1 with the O ring Remove oil screen 2 with the O ring Completely drain the engine oil Clean the oil drain plug and oil screen thoroughly Position oil screen 2 and mount and tighten oil drain plug O with the O ring Guideline Oil drain plug RC 125 M24x1 5 15 Nm 11 1 Ibf ft Oil drain plug RC 200 M24x1 5 15 Nm 11 1 Ibf ft 18 SERVICE WORK ON THE ENGINE 160 Remove screws O Remove the oil filter cover o with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area Insert oil filter O Lubricate the O ring of the oil filter cover Mount the oil filter cover Mount and tighten the screws Guideline Screw oil filter cover RC 125 M5 8 Nm 5 9 Ibf ft Screw oil filter cover RC 200 M5 8 Nm 5 9 Ibf ft e Info L02170 10 Too little engine oil or poor quality engine oil results in premature wear to the engine 18 SERVICE WORK ON THE ENGINE 161 Remove the oil filler plug QO with the O ring from the clutch cover and fill up with engine oil 50 Engine oil 1 51 1 6 qt Outside temper Engine oil ature O 50 C SAE 15W 50 32 122 F p 192 Outside tempera Engine oil ture 10 40 C SAE 10W 40
106. r road use p 195 400725 01 Finishing work Take the motorcycle off of the rear wheel stand p 78 12 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary 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 e Info The upper chain section B must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Chain tension 5 7 mm 0 2 0 28 in Ifthe chain tension does not meet specifications Adjust the chain tension p 87 See gt pc E 1 L02128 10 87 12 SERVICE WORK ON THE CHASSIS 12 12 Adjusting the chain tension Warning Danger of accidents Danger
107. rear brakes at the same time On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed 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 Stopping parking A Note Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 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
108. ress your hand on the screw to push the wheel spindle out of the axle clamp Remove screw A Warning A 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 dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed A Warning A tA Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 117 Main work RC 200 Remove spacers O Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the front wheel bearing 4 Clean and grease the shaft seal rings and mating surfaces O of the spacers Long life grease p 195 Insert the spacers Clean the thread of the wheel spindle and screw 6 Position the front wheel and insert the wheel spindle Y The brake linings are correctly positioned Mount and tighten screw 6 Guideline Screw front wheel spindle M8 20 Nm 14 8 Ibf ft Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Take the motorcycle off of the front wheel stand p 80 Pull
109. roduct Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 196 Oil the ignition steering lock Universal oil spray p 196 19 2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt E E O dE Z E Oy MAS eN m 3 X 401060 01 Clean the motorcycle p 163 Clean the brakes e Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well 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 e 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 84 20 20 1 STORAGE Storage 167 Info If you want to garage the motorcycle for a longer period take the followi
110. s LED Turn signal LED Brake tail light LED License plate lamp LED Front tires 110 70 R 17 M C 54S TL MRF revz FC Rear tires 150 60 R 17 M C 66S TL MRF revz C Additional information is available in the Service section under http www ktm com Fork part number 90501000000 Fork WP Suspension Fork length 736 mm 28 98 in Fork oil 460 ml 15 55 fl oz Fork oil SAE 4 4860116681 p 193 Shock absorber part number 90504010000 Shock absorber WP Suspension Spring preload Comfort 1 click Standard 4 clicks 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 Ibf ft Screw chain guard EJOT PT K60x30 4 Nm 3 Ibf ft Remaining nuts chassis MA 3 Nm 2 2 Ibf ft Remaining screws chassis MA 3 Nm 2 2 Ibf ft Screw EFI control unit MA 3 Nm 2 2 Ibf ft Nut reflector on retaining plate M5 7 Nm 5 2 Ibf ft Nut retaining plate on license plate M5 4 Nm 3 Ibf ft holder Remaining nuts chassis M5 5 Nm 3 7 Ibf ft Remaining screws chassis M5 5 Nm 3 7 Ibf ft Screw ABS hose clamp RC 125 M5 6 Nm 4 4 Ibf ft Screw anti rota
111. s motorcycle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops 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 1 button for 3 5 seconds Y The ABS warning lamp starts flashing ABS is deactivated lg 401685 15 Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully e Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions A Warning 2 Danger of accidents If you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can lock up Fr ee p P RIDING INSTRUCTIONS 64 Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the
112. sting the o range of the high beam Main work Adjust the beam distance of the high beam by turning screw O 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 high beam headlight setting e Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range L02163 10 Finishing work Check the high beam headlight adjustment p 143 16 COOLING SYSTEM 145 36 1 Cooling system 5595959595950 Water pump 1 in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap O Heat expansion causes excess coolant to flow into compensating tank O 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 125 C 257 F L02160 10 16 COOLING SYSTEM 146 The coolant is cooled by the air stream and a radiator fan O which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 402242 10 Warning gt Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure
113. tart system is inactive 402029 10 7 COMBINATION INSTRUMENT 34 Display p 41 Function buttons p 39 Info display p 45 Indicator lamps p 40 AJl N e 401685 10 7 COMBINATION INSTRUMENT 35 NS E 595550 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 O to 199 and back The remaining display segments outside the info display light up briefly The READY TO RACE gt gt logo appears on the info display The display then changes to the last selected mode 401686 01 7 COMBINATION INSTRUMENT 36 73 Wamimgmtes 00000 Low Oil Pressure appears on the info display if the oil pressure is too low Low Fuel Level appears on the info display if the fuel level reaches the reserve mark 7 COMBINATION INSTRUMENT the specified value 31 High Coolant Temperature appears on the info display if the coolant temperature rises above Coolant temperature 125 C 257 F Side Stand Down appears on the info display if the side stand is folded down Low Battery appears on the info display if the battery voltage falls below the specified value Battery voltage 10 80 V 7 COMBINATION INSTRUMENT 38 Service Not Reset appears on the info display
114. tcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage Ifthe tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly 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 distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 125 kg 276 Ib Maximum permissible rear axle load 210 kg 463 Ib 9 RIDING INSTRUCTIONS 9 1 Checks and maintenance when preparing for use e Info Before every trip check t
115. tendency of a wheel to lock the ABS begins regu 402052 10 lating the braking pressure The control process causes the hand and foot brake levers to vibrate slightly 13 BRAKE SYSTEM 13 2 Checking the brake discs Warning Danger of accidents 104 The ABS warning lamp e 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 The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning lamp goes out when you start off Button o can be used to switch ABS off manually see Starting Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 400480 10 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement O
116. the front brake and compress the fork forcefully a few times Y The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft 14 WHEELS TIRES 118 RC 125 Remove spacers O Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the front wheel bearing 4 Clean and grease the shaft seal rings 2 and mating surfaces O of the spacers Long life grease p 195 Insert the spacers Clean the thread of the wheel spindle and screw Position the front wheel and insert the wheel spindle Y The brake linings are correctly positioned Mount and tighten screw 6 Guideline Screw front wheel spindle M8 20 Nm 14 8 Ibf ft Position wheel speed sensor o in the drill hole Mount and tighten screw O Guideline Screw wheel speed sensor M6 9 Nm Loctite 243 holder 6 6 Ibf ft Mount and tighten screws Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Take the motorcycle off of the front wheel stand p 80 Pull the front brake and compress the fork forcefully a few times Y The fork legs straighten 14 WHEELS TIRES 119 Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft Finishing work Take the motorcycle off of the front wh
117. the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 13 BRAKE SYSTEM L02135 11 Disconnect spring O Release nut and use screw to adjust the specified free travel O Guideline 114 3 5 mm 0 12 0 2 in Free travel at foot brake lever e Info The range of adjustment is limited Hold screw e and tighten nut e Attach spring O 14 WHEELS TIRES 115 14 1 Removing the front wteel 5550 Preparatory work Raise the motorcycle with the rear wheel stand p 78 Raise the motorcycle with the front wheel stand p 79 Main work RC 200 Loosen screw 1 and screws e Unscrew screw o 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 Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed 14 WHEELS TIRES 116 RC 125 Remove screws and push the fender to the side Remove screw e and pull wheel speed sensor e out of the hole Loosen screw o and screws O Unscrew screw o about 6 turns and p
118. thiness After a fall check the vehicle as usual before preparing for use Note Engine failure Overheating of engine Ifthe coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to cool down and check the coolant level in the radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure e Iinfo If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop 90000 4 O ar 401950 11 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 4 bars of the temperature indicator light up 9 9 5 RIDING INSTRUCTIONS 66 Accelerate only up to a speed suitable for the road surface and weather conditions Par ticularly 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
119. tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 158 19 CLEANING CARE 163 19 1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pres sure can cause malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust system to keep water out N First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paint brush Motorcycle cleaner p 195 401061 01 19 CLEANING CARE 164 e Info Use warm water containing normal motorcycle cleaner and
120. tion lock handlebar stub M5 4 Nm 3 Ibf ft Screw battery compartment M5 4 Nm 3 Ibf ft Screw chain guard M5 7 Nm 5 2 Ibf ft Loctite 2047 Screw cover in front of battery compart M5 4 Nm 3 Ibf ft ment Screw fuel pump M5 5 Nm 3 7 Ibf ft Screw fuel tank cover M5 5 Nm 3 7 Ibf ft 23 TECHNICAL DATA 188 Screw rollover sensor M5 6 Nm 4 4 Ibf ft Loctite 243 Screw side stand switch M5 5 Nm 3 7 Ibf ft Loctite 243 Screw tail end lower part M5 4 Nm 3 Ibf ft Cap bolt footrest M6 9 Nm 6 6 Ibf ft Nut foot brake lever adjustment M6 10 Nm 7 4 Ibf ft Nut license plate bracket M6 8 5 Nm 6 27 Ibf ft Nut shift rod M6 10 Nm 7 4 Ibf ft Nut shift rod M6LH 10 Nm 7 4 Ibf ft Nut tail light M6 7 Nm 5 2 Ibf ft Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft Screw ABS module on ABS module M6 7 Nm 5 2 Ibf ft retaining bracket RC 125 Screw ABS module retaining bracket on M6 7 Nm 5 2 Ibf ft silent block RC 125 Screw air filter box lid M6 3 Nm 2 2 Ibf ft Screw air filter box on frame M6 6 Nm 4 4 Ibf ft Screw battery compartment M6 6 Nm 4 4 Ibf ft Screw brake fluid container front brake M6 8 Nm 5 9 Ibf ft Screw brake fluid container rear brake M6 7 Nm 5 2 Ibf ft Screw brake line guide on bottom tr
121. to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Very forceful braking can cause the wheels to block ABS must be switched on to be effective When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery ter rain without locking of the wheels A A Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed 9 RC 200 9 6 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 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
122. u dd 87 CHECKING acosa bale rd e arte bhai to VE Ea 85 Chassis number syaa reanna a aaa aa r ED a a E o i aaa 20 Clutch cable play adj sStiNg z usce A to Q kn ES 157 Glutehilever cir A a Lae a e 22 Clutch lever play CHECKING ia E AA 156 Combination instrument activation and test XY kk kK KK K K RR RR KK 35 INDEX average fuel consumption l average fuel consumption 2 MC EAE A dh rd 47 average fuel consumption 2 service menu 48 average speed average fuel consumption 1 menu 46 coolant temperature indicator o o o ooooooo 44 displays a A dk V bee deed od yA dd a a ee Wa A A d n deat E 41 display TRIP ooo a k Aka dard WA kd dese ee an 43 distance menu 1 TRIP1 A A KK KK KI KK 51 distance menu 2 TRIP2 o o o 52 filling level display in fuel tank o o ooooo 42 FUNCTION DUTON eee os sii wa ia dim dne ES 39 indicator lamps lesse 40 info dISplay s r al GA AE a ke do oe E XU 45 range riding time menu kk KK KIRI KIRI K K KII o 50 riding time average speed menu 2 KII 46 service range MENU a Pid ed KI ro KI bear dw KIR 49 total distance menu ODO 2 00005 51 Warning notes ss seca rar ilo eR p eus cid Bau 36 Coolant dralnine atar ta e at fa 151 Coolant level CHECKING eu a e Oe ik a a Bea 148 compensating tank checking cles 146 compensating tank correcting css 1
123. untries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 725 45 C 13 anti corrosion antifreeze 49 F distilled water Recommended supplier Motorex COOLANT M3 0 Standard classification JASO T903 MA p 197 SAE p 197 SAE 15W 50 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 Standard classification JASO T903 MA p 197 SAE p 197 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Partially synthetic engine oil Recommended supplier Motorex Formula 4T Standard classification SAE p 197 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding proper ties 24 SUBSTANCES 194 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 e Info

12 service work on the chassis

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