KTM FREERIDE E-XC Owner's Manual
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KTM FREERIDE E-XC Owner's Manual

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OWNER'S MANUAL
2016
Freeride E-SX
Freeride E-XC
Art. no.3213342en

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Summary of Contents for KTM FREERIDE E-XC

  • Page 1 OWNER'S MANUAL 2016 Freeride E-SX Freeride E-XC Art. no.3213342en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    Deactivating the vehicle........37 (Freeride E‑SX) ..........17 Transporting the vehicle ........38 View of vehicle, rear right (example) Transporting the KTM PowerPack ..... 38 (Freeride E‑SX) ..........18 10 SERVICE SCHEDULE ..........39 View of vehicle, front left (example) 10.1...
  • Page 5 12.19 Installing the shock absorber ......62 battery(Freeride E‑XC) ........94 12.20 Folding the seat up ......... 63 16 KTM POWERPACK, BATTERY CHARGER ..... 96 12.21 Locking the seat ..........63 16.1 Removing the KTM PowerPack ......96 12.22 Removing the spoiler........63 16.2...
  • Page 6 TABLE OF CONTENTS 23.7 Fork............. 119 23.8 Shock absorber ..........119 23.9 Chassis tightening torques ......120 24 SUBSTANCES ............121 25 AUXILIARY SUBSTANCES ........122 26 STANDARDS ............123 27 INDEX OF SPECIAL TERMS ........124 28 LIST OF ABBREVIATIONS......... 125 29 LISY OF SYMBOLS...........

  • Page 7: Means Of Representation

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

  • Page 8: Safety Advice

    SAFETY ADVICE Use definition - intended use (Freeride E‑SX) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info Only operate the vehicle in closed-off areas remote from public road traffic. Only use the lithium-ion battery while it is inside the vehicle.

  • Page 9: Safety Instructions And Warning Labels(Freeride E-Sx)

    SAFETY ADVICE Safety instructions and warning labels(Freeride E‑SX) C00852-10 Info The safety instructions are highlighted in the text. The vehicle has warning labels in prominent locations. Do not remove any warning labels, or else you or others may fail to recognize sources of danger and become injured. Chain tension Multifunction display High-voltage components...
  • Page 10 SAFETY ADVICE Multifunction display C00841-01 High-voltage components C00772-01 Rechargeable lithium-ion battery C00773-01 Use guidelines 1 C00843-01 Use guidelines 2 C00840-01 Use guidelines 3 C00844-01...
  • Page 11 SAFETY ADVICE High-voltage components, see the Repair Manual C00848-01 Initial start-up C00838-01 High-voltage components and electric shock, see the Owner's Manual C00842-01 Suitable brake fluid C00845-01 C00839-01 Use definition Vehicle without approval for use on public roads C00847-01...

  • Page 12: Safety Instructions And Warning Labels(Freeride E-Xc)

    SAFETY ADVICE Safety instructions and warning labels(Freeride E‑XC) C00853-10 Info The safety instructions are highlighted in the text. The vehicle has warning labels in prominent locations. Do not remove any warning labels, or else you or others may fail to recognize sources of danger and become injured. Multifunction display Chain tension High-voltage components...
  • Page 13 SAFETY ADVICE Chain tension C00846-01 High-voltage components C00772-01 Rechargeable lithium-ion battery C00773-01 High-voltage components, see the Repair Manual C00848-01 Initial start-up C00838-01 High-voltage components and electric shock, see the Owner's Manual C00842-01...

  • Page 14: Tampering Warning

    SAFETY ADVICE Suitable brake fluid C00845-01 C00849-01 Type label for EU Anti-manipulation label C00850-01 Tampering warning Modifying the vehicle is prohibited, as otherwise safe operation cannot be guaranteed. Examples of unlawful manipulation and modifications: 1 Opening the rechargeable lithium-ion battery or the motor. 2 Using the vehicle or the rechargeable lithium-ion battery in the event of a lack of proper maintenance.

  • Page 15: Fall Or Accident

    When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the applicable laws and regula- tions in your country. When disposing of the lithium-ion battery (KTM PowerPack) and the 12 V battery, comply with the laws and regulations of the respec- tive country.

  • Page 16: Owner's Manual

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

  • Page 17: Important Notes

    Guarantee, warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. No warranty claims can be con- sidered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 18: System Voltage

    The fuse box is located next to the 12 V battery. The KTM PowerPack is located under the seat and is bolted to the electric motor. The KTM PowerPack can be removed with just a few simple steps.

  • Page 19: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example)(Freeride E‑SX) C00671-10 Front brake lever ( p. 23) Rear brake lever ( p. 23) Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 25)

  • Page 20: View Of Vehicle, Rear Right (Example)(Freeride E-Sx)

    VIEW OF VEHICLE View of vehicle, rear right (example)(Freeride E‑SX) C00672-10 Multifunction display ( p. 27) Main switch ( p. 23) Start button ( p. 24) Throttle grip ( p. 23) Fork rebound adjustment Fork compression adjustment KTM PowerPack...

  • Page 21: View Of Vehicle, Front Left (Example)(Freeride E-Xc)

    VIEW OF VEHICLE View of vehicle, front left (example)(Freeride E‑XC) C00789-10 Front brake lever ( p. 23) Rear brake lever ( p. 23) Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 25)

  • Page 22: View Of Vehicle, Rear Right (Example)(Freeride E-Xc)

    27) Horn button ( p. 24) Light switch ( p. 24) Turn signal switch ( p. 24) Main switch ( p. 23) Start button ( p. 24) Throttle grip ( p. 23) Fork rebound adjustment Fork compression adjustment KTM PowerPack...

  • Page 23: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label  is located on the front steering head. 401946-10 Motor number  The motor number is located on the left side of the motor over the motor sprocket. 402364-10 Fork part number The fork part number...

  • Page 24: Battery Identification Number

    SERIAL NUMBERS Battery identification number  The battery identification number (BIN) is stamped under the handle of the KTM PowerPack. C00771-10...

  • Page 25: Controls

    CONTROLS Front brake lever  The front brake handle is fitted on the right side of the handlebar. C00791-10 Rear brake lever (Freeride E‑SX)  The rear brake lever is fitted on the left side of the handlebar. C00678-10 (Freeride E‑XC) ...

  • Page 26: Start Button

    CONTROLS Start button  The start button is fitted on the right side of the handlebar. The start button is only enabled when the main switch is switched on. When the start button is pushed, the vehicle switches from standby to ready mode. The driving mode indicator and an acoustic signal indicate operating readiness.

  • Page 27: Side Stand

    When the ignition is switched on and the main switch is switched off, the 12 V battery discharges very quickly because in this case the lighting is powered by the 12 V battery instead of the KTM PowerPack. Possible states C00825-10 Ignition off–...

  • Page 28: Locking The Steering(Freeride E-Xc)

    CONTROLS 6.12 Locking the steering(Freeride E‑XC) 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. – Push the main switch into the position –...

  • Page 29: Display

    DISPLAY Multifunction display 7.1.1 Multifunction display The multifunction display is attached in front of the seat. Overview of the multifunction display Map-select tip switch ( p. 27) Driving mode display ( p. 27) Electric motor indicator lamp ( p. 28) Charge level indicator ( p.

  • Page 30: Electric Motor Indicator Lamp (Mil)

    9 °C and 50% of power at temperatures of less than 0 °C. 402363-10 When the KTM PowerPack has warmed up sufficiently, 80% of power or full power is available, depending on the temperature, once the vehicle has been started again.

  • Page 31: Overview

     flashes slowly and the charge level indicator lights up red or flashes red: – The charge state of the KTM PowerPack is below 20%. Vehicle power is reduced. Switch off the vehicle and charge the KTM PowerPack. Overview 7.2.1 Indicator lamps overview(Freeride E‑XC)

  • Page 32: Message On The Speedometer

    7.3.3 Message on the speedometer Possible states Battery voltage of the speedometer– Battery voltage of the speedometer is too low. Change the battery. Service– A service is due. Contact an authorized KTM workshop. 401901-01 7.3.4 Setting the speedometer Condition The motorcycle is stationary.

  • Page 33: Setting The Kilometers Or Miles

    DISPLAY Switching off the service interval display – Press and hold the left button. The value decreases rapidly until off appears in the display. 401914-01 7.3.5 Setting the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary.

  • Page 34: Speed, Time, And Dst Distance 1

    DISPLAY – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the service display to flash. – Set the service. Guideline One-time service after Service every 20 h Shortening the service interval 401913-01 –...

  • Page 35: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    DISPLAY DST2 is reset to 0.0. Press the right but- ton for 3 – 5 sec- onds. 7.3.10 AVG average speed, ART operating hours, and ODO total distance covered – Press one of the buttons until AVG, ART and ODO appear in the speedometer. AVG shows the average speed since the last reset.

  • Page 36: Preparing For Use

    Protect the vehicle against access by unauthorized persons. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You will receive the delivery documents and the Service and Warranty Booklet at vehicle handover.

  • Page 37: Riding Instructions

    Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the throttle grip, main switch, KTM PowerPack, multifunction display and electric motor for external damage. (Freeride E‑XC) –...

  • Page 38: Starting Off

    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 Reduced braking efficiency due to a wet or dirty brake system.

  • Page 39: Stopping, Parking

    RIDING INSTRUCTIONS – Try to complete the braking procedure before riding into a curve. Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Never leave the vehicle unattended. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.

  • Page 40: Transporting The Vehicle

    Secure the KTM PowerPack with tension belts or other suitable fixing materials. – To ensure rapid access in the event of an emergency, always transport the KTM PowerPack close to the cargo door. – Transport the KTM PowerPack separately from flammable liquids or ignition sources such as fuel, gas, or oil.

  • Page 41: Service Schedule

    ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 42: Service Work (As Additional Order)

    SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 100 operating hours Every 50 operating hours Every 20 operating hours after sporting use ● Change the front brake fluid. ● Change the rear brake fluid. ● Grease the steering head bearing. p.

  • Page 43: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided.(Your authorized KTM workshop will be glad to help.) Info The low-speed setting takes effect during slow to normal compression of the shock absorber.

  • Page 44: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided.(Your authorized KTM workshop will be glad to help.) Info The high-speed setting takes effect during fast compression of the shock absorber.

  • Page 45: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided.(Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 46: Checking The Static Sag Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided.(Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 47: Adjusting The Riding Sag

    TUNING THE CHASSIS – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p. 49) – Remove the shock absorber. p. 62) – After removing the shock absorber, clean it thoroughly.

  • Page 48: Checking The Basic Setting Of The Fork

    Remove the motorcycle from the lift stand. ( p. 49) – Adjust the rebound damping of the shock absorber. ( p. 43) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) – Check the static sag of the shock absorber. ( p.

  • Page 49: Adjusting The Rebound Damping Of The Fork

    If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64)
  • Page 50 Position the handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap widths are even. Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63)

  • Page 51: Service Work On The Chassis

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work – Use the motor guard underneath the motor to raise the vehicle.

  • Page 52: Cleaning The Dust Boots Of The Fork Legs

    Tighten the bleeder screws. C00796-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 12.4 Cleaning the dust boots of the fork legs Preparatory work –...

  • Page 53: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS Main work (Freeride E‑SX) –  Remove screws and take off the clamp. –  Remove screws and the spacers and take off the brake caliper. – Allow the brake caliper and brake line to hang tension-free to the side. C00689-10 –...
  • Page 54 Install the start number plate. ( p. 61) (Freeride E‑XC) – Refit the headlight mask with the headlight. ( p. 92) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) (Freeride E‑XC) – Check the headlight setting. (...

  • Page 55: Removing The Fork Protector

    Removing the fork protector Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work (Freeride E‑SX) – ...

  • Page 56: Removing The Lower Triple Clamp

    – Position the brake line, wiring harness, and clamp. Mount and tighten  screws C00801-11 Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 12.9 Removing the lower triple clamp Preparatory work –...

  • Page 57: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS (Freeride E‑XC) –  Open holder and detach the wiring harness and brake line. C00835-10 –  Remove screw –  Remove screw – Take off the upper triple clamp with the handlebar and set it aside. Info Cover the components to protect them against damage.
  • Page 58 SERVICE WORK ON THE CHASSIS – Position the fork legs.  Bleeder screws face forward. Info The lowest milled groove in the fork leg must be flush with the top edge of the upper triple clamp. The support for the brake caliper is attached to the left fork leg. C00696-10 –...
  • Page 59 SERVICE WORK ON THE CHASSIS –  Position the brake caliper. Mount and tighten screws with the spacers. Guideline Screw, front brake 25 Nm Loctite ® 243™ caliper (18.4 lbf ft) –  Position the brake line and clamp. Mount and tighten screws C00856-10 (Freeride E‑XC) –...
  • Page 60 Check that the cable and brake lines are routed correctly. – Check the play of the steering head. p. 59) – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63)

  • Page 61: Checking The Play Of The Steering Head

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay.(Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 62: Greasing The Steering Head Bearing

    Check the play of the steering head. p. 59) – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 12.13 Greasing the steering head bearing –...

  • Page 63: Installing The Start Number Plate(Freeride E-Sx)

    10 Nm (7.4 lbf ft) – Position the brake line and clamp. –  Mount and tighten screw C00720-11 Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 12.16 Removing the front fender Preparatory work –...

  • Page 64: Removing The Shock Absorber

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p.

  • Page 65: Folding The Seat Up

    Removing the spoiler Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work –  Remove screws C00763-10 –...

  • Page 66: Installing The Spoiler

    63) 12.24 Mounting the covering cap Note Material damage Components damaged or destroyed by water or dirt. – Mount the covering cap if you have removed the KTM PowerPack. Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p.

  • Page 67: Removing The Covering Cap

    SERVICE WORK ON THE CHASSIS 12.25 Removing the covering cap Note Material damage Components damaged or destroyed by water or dirt. – Mount the covering cap if you have removed the KTM PowerPack. Main work – Remove the covering cap  with one hand.

  • Page 68: Checking The Chain Tension

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p.

  • Page 69: Adjusting The Chain Tension

    Adjust the chain tension. p. 67) Finishing work – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 12.30 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.

  • Page 70: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p.

  • Page 71: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must be replaced. Repair of the frame is not authorized by KTM. 402151-01...

  • Page 72: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 402152-01 Finishing work – Install the KTM PowerPack. ( p.

  • Page 73: Brake System

    BRAKE SYSTEM 13.1 Checking the free travel of the front brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the front brake lever, pressure builds up on the front brake circuit. –...

  • Page 74: Checking The Brake Discs

    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.) (Freeride E‑SX) –...

  • Page 75: Adding Front Brake Fluid

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

  • Page 76: Checking The Front Brake Linings

    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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 77 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 78 Position the cover with the membrane. Mount and tighten the screws. M00686-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63)

  • Page 79: Checking The Free Travel Of The Rear Brake Lever

    BRAKE SYSTEM 13.9 Checking the free travel of the rear brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the rear brake lever, pressure builds up on the rear brake circuit. –...

  • Page 80: Checking The Rear Brake Fluid Level

    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.) (Freeride E‑SX) –...

  • Page 81: Checking The Rear Brake Linings

    96) – Lock the seat. ( p. 63) 13.14 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately.(Your authorized KTM workshop will be glad to help.)

  • Page 82: Changing The Rear Brake Linings

    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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 83 BRAKE SYSTEM Main work (Freeride E‑SX) – Move the brake fluid reservoir attached to the left of the handlebar to a horizon- tal position. – Remove screws  –   Remove cover with membrane – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir, extracting brake fluid if necessary.
  • Page 84 Position the cover with the membrane. Mount and tighten the screws. M00685-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63)

  • Page 85: Wheels, Tires

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p.

  • Page 86: Removing The Rear Wheel

    –  Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 14.3 Removing the rear wheel Preparatory work – Deactivate the vehicle. ( p.

  • Page 87: Installing The Rear Wheel

    Operate the rear brake lever several times until the brake linings are in contact with the brake disc and there is a pressure point. C00707-11 Finishing work – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63)

  • Page 88: Checking The Tire Condition

    The first two digits refer to the week of manufac- ture and last two digits refer to the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 89: Checking The Spoke Tension

    14.7 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct.(Your authorized KTM workshop will be glad to help.) Preparatory work – Deactivate the vehicle. ( p. 37) –...

  • Page 90: Electrical System

    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. Preparatory work –...

  • Page 91: Recharging The 12 V Battery

    – 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 discharges steadily.

  • Page 92: Changing The Fuses Of Individual Power Consumers

    Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work –  Detach the catches and open the fuse box cover.

  • Page 93: Removing The Headlight Mask With The Headlight(Freeride E-Xc)

    – Check that the power consumer is functioning properly. – Close the fuse box cover and allow the catches to engage. Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 15.5 Removing the headlight mask with the headlight(Freeride E‑XC) Preparatory work –...

  • Page 94: Refitting The Headlight Mask With The Headlight(Freeride E-Xc)

    Position the headlight mask and fix it with rubber straps The holding lugs engage. –  Position the brake line and wiring harness C00851-10 Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) – Check the headlight setting. ( p. 94) 15.7...

  • Page 95: Changing The Turn Signal Bulb(Freeride E-Xc)

    Insert the bulb socket of the parking light into the reflector. Finishing work – Refit the headlight mask with the headlight. ( p. 92) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) –...

  • Page 96: Checking The Headlight Setting(Freeride E-Xc)

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Remove the headlight mask with the headlight. ( p.
  • Page 97 Mount and tighten the screws with washers. C00821-10 Finishing work – Refit the headlight mask with the headlight. ( p. 92) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) – Check the headlight setting. ( p.

  • Page 98: Ktm Powerpack, Battery Charger

    Note Material damage Components damaged or destroyed by water or dirt. – Before installing the KTM PowerPack, check that the battery discharge plug on the electric motor and the battery discharge socket on the KTM PowerPack are clean. – Check the battery discharge plug form ring.

  • Page 99: Overview Of The Ktm Powerpack Battery Charger

    –  Position the KTM PowerPack in the vehicle. The KTM PowerPack is resting flush on the electric motor. Info The KTM PowerPack is very heavy. A second person can help with installa- tion. –  Tighten screws Guideline KTM PowerPack attachment 10 Nm (7.4 lbf ft)

  • Page 100: Positioning The Battery Charger

    Ensure that no fluids flow or drip onto the battery charger. Warning Risk of injury If the battery charger is used incorrectly, its intrinsic safety cannot be guaranteed. The battery charger is only suitable for use with a KTM PowerPack. – Only use the battery charger with a KTM PowerPack.

  • Page 101: Recharging The Ktm Powerpack

    The KTM PowerPack will continue to be recharged, however the 12 V battery will stop recharging. Info When the left LED in the charge level indicator on the battery charger flashes, then the KTM PowerPack is ready for use. How- ever, its full capacity will not yet be available.

  • Page 102: Charging The Ktm Powerpack In The Storage Charging Mode

    Environmental hazard Lithium-ion batteries contain components and elements that are harmful to the environment. – Never throw a KTM PowerPack into the household trash. – Dispose of the KTM PowerPack properly and in compliance with the applicable regulations.(Your authorized KTM workshop will be glad to help.)
  • Page 103 The charge level of the KTM PowerPack must be below 50% before the Storage charging mode can be used. If the temperature of the KTM PowerPack exceeds the permissible value while it is being charged, the charger stops charging. All LEDs and the LEDS for the current charge level alternately light up every second.

  • Page 104: Changing Charging Socket Protection Cap

    Risk of injury There is a risk of electric shock when working on high-voltage components. Work on high-voltage components requires special training, qualifications and tools. – Have all work that is not described and explained performed by trained KTM mechanics only. – Do not open the electric motor or the lithium-ion battery (KTM PowerPack).
  • Page 105 KTM POWERPACK, BATTERY CHARGER – Position carry handle. Guideline Do not pinch the loop between the KTM PowerPack and the carry handle. – Mount and tighten screws  Guideline Screws, carry handle 5 Nm (3.7 lbf ft) M00745-10 Finishing work –...

  • Page 106: Cooling System

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) – Raise the motorcycle with a lift stand. ( p.

  • Page 107: Checking The Coolant Level

    COOLING SYSTEM – Mount the radiator cap. Finishing work – Remove the motorcycle from the lift stand. ( p. 49) – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) 17.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

  • Page 108: Refilling With Coolant

    The motor is cold. Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work –  ...

  • Page 109: Tuning The Motor

    TUNING THE MOTOR 18.1 Selecting the driving mode Condition Alternative1 The motorcycle is stationary. The motorcycle is ready for operation. Alternative2 The motorcycle is stationary. The motorcycle is ready to drive. Alternative3 The motorcycle is moving. ≤ 5 km/h (≤ 3.1 mph) The throttle grip is in the basic position.

  • Page 110: Service Work On The Motor

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 96) – Mount the covering cap. ( p. 64) Main work – Place a suitable container under the motor.
  • Page 111 8 Nm (5.9 lbf ft) – Stand the motorcycle upright. C00745-11 Finishing work – Install the KTM PowerPack. ( p. 96) – Lock the seat. ( p. 63) – Go for a short test ride and check the motor has no leaks.

  • Page 112: Cleaning, Care

    The high pressure allows water to penetrate electrical components, plugs, bearings, etc. This results in components being damaged or destroyed. – Never clean the vehicle and the KTM PowerPack with high-pressure cleaning equipment or a strong jet of water. Note Material damage Water or dirt damage or destroy components.

  • Page 113: Checks And Maintenance Steps For Winter Operation(Freeride E-Xc)

    CLEANING, CARE 20.2 Checks and maintenance steps for winter operation(Freeride E‑XC) Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 114: Storage

    Preparing for use after storage Info If the KTM PowerPack has not been used for more than six months, start by discharging the KTM PowerPack until the vehicle switches off with blink code 11. Then recharge the KTM PowerPack completely.

  • Page 115: Troubleshooting

    15 seconds, and then switch the vehicle back on. If a fault is not eliminated by the measures specified here, or a blink code is not listed, an authorized KTM workshop will be happy to help you. Info The pause between the signals of the 1st digit is 0.25 seconds.
  • Page 116 TROUBLESHOOTING Faults Possible cause Action – Fuse 3 blown The high beam, low beam, parking Change the fuses of individual power light, tail light, and license plate consumers. ( p. 90) lamp are not working (Freeride E‑XC) – The speedometer, horn, brake light, Fuse 4 blown Change the fuses of individual power and turn signal are not working...

  • Page 117: Troubleshooting Of The Battery Charger

    15 seconds, and then switch it back on. If a fault is not eliminated by the measures specified here, or a blink code is not listed, an authorized KTM workshop will be happy to help you. Info The pause between the signals of the 1st digit is 0.25 seconds.

  • Page 118: Troubleshooting Of The Ktm Powerpack When Connected To The Battery Charger

    The first step to take in case of any fault is to switch off the battery charger, wait for 15 seconds, and then switch it back on. If a fault is not eliminated by the measures specified here, an authorized KTM workshop will be happy to help you.

  • Page 119: Technical Data

    TECHNICAL DATA 23.1 Motor Design Permanent magnet synchronous motor with a disc motor design Primary transmission 1:2.4 Cooling Water cooling, permanent circulation of coolant by electric water pump Nominal power 11 kW (15 hp) Electric peak performance 16 kW (21 hp) Maximum torque 42 Nm (31 lbf ft) Maximum motor speed...

  • Page 120: Electrical System

    TECHNICAL DATA Ground clearance, unloaded 340 mm (13.39 in) Seat height, unloaded 910 mm (35.83 in) Weight with KTM PowerPack approx.(Freeride E‑SX) 106 kg (234 lb.) Homologated weight with KTM PowerPack 110 kg (243 lb.) approx.(Freeride E‑XC) Maximum permissible front axle load 135 kg (298 lb.)

  • Page 121: Fork

    TECHNICAL DATA 23.7 Fork Fork part number 05.18.7N.41 Fork WP Performance Systems 4357 MXMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Spring length with preload spacer(s) Weight of rider:65…...

  • Page 122: Chassis Tightening Torques

    Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) – Screws, throttle grip 3 Nm (2.2 lbf ft) – KTM PowerPack attachment 10 Nm (7.4 lbf ft) – Remaining nuts, chassis 10 Nm (7.4 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 123: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...

  • Page 124: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Grip adhesive(00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner...

  • Page 125: Standards

    STANDARDS The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis- cosity. The viscosity describes only one property of oil and says nothing about quality.

  • Page 126: Index Of Special Terms

    INDEX OF SPECIAL TERMS Electric motor control lamp (Malfunction Error indicator light that allows vehicle diagnostics through blink Indicator Lamp) codes...

  • Page 127: List Of Abbreviations

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

  • Page 128: Lisy Of Symbols

    LISY OF SYMBOLS 29.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Electric motor indicator lamp flashes– A error is present in the vehicle electronic system. 29.2 Green and blue symbols Green and blue symbols reflect information.

  • Page 129: Index

    INDEX Compression damping, high-speed INDEX shock absorber, adjusting ..... 42 12-V battery Compression damping, low-speed installing ....... . . 88 shock absorber, adjusting .
  • Page 130 ....... . . 38 KTM PowerPack work ........13 Battery identification number (BIN) .
  • Page 131 ......115 of KTM PowerPack on battery charger ... . 116 vehicle .
  • Page 132 *3213342en* 3213342en 06/2015 KTM Sportmotorcycle GmbH 5230Mattighofen/Austria Photo:Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

Freeride e-sx

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