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KTM Freeride E-XC 2019 Owner's Manual

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OWNER'S MANUAL
2019
Freeride E-XC
Art. no. 3213862en

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Summary of Contents for KTM Freeride E-XC 2019

  • Page 1 OWNER'S MANUAL 2019 Freeride E-XC Art. no. 3213862en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    Customer service......13 Setup menu ........30 System voltage ........ 14 8.10 Adjusting the unit of measurement ..31 New KTM PowerPack ....... 14 8.11 Display mode SPEED/CLK (time) ..32 Operation at low temperatures... 14 8.12 Adjusting the clock ......32 VIEW OF VEHICLE ........
  • Page 5 ..........65 10.8 Transporting the vehicle ....44 13.13 Greasing the steering head 10.9 Transporting the KTM PowerPack ..44 bearing ........66 13.14 Removing front fender ...... 66 11 SERVICE SCHEDULE ........45 13.15 Installing front fender....... 67 11.1...
  • Page 6 24.6 Tires ..........134 instrument battery......106 24.7 Fork..........134 24.8 Shock absorber ......134 17 KTM POWERPACK, BATTERY CHARGER ..107 24.9 Chassis tightening torques ....135 17.1 Removing the KTM PowerPack ..107 25 SUBSTANCES .......... 137 17.2 Installing the KTM PowerPack..

  • Page 7: Means Of Representation 1

    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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of offroad use. Info This vehicle is only authorized for operation on public roads in its homologated version. Only use the lithium-ion battery while it is inside the vehicle.

  • Page 9: Safety Instructions And Warning Labels

    SAFETY ADVICE 2 Safety instructions and warning labels F01659-10 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.
  • Page 10 2 SAFETY ADVICE Chain tension C00846-01 Multifunction display A00172-10 High-voltage components C00772-01 High-voltage components and electric shock F01663-01 Rechargeable lithium-ion battery A00171-10...
  • Page 11 SAFETY ADVICE 2 High-voltage components and electric shock F01661-01 High-voltage components, see the Repair Manual C00848-01 Initial start-up A00207-10 High-voltage components and electric shock, see the Owner's Manual C00842-01 Suitable brake fluid C00845-01...

  • Page 12: Tampering Warning

    Examples of unlawful manipulation and modifications: 1 Opening the rechargeable lithium-ion battery (KTM PowerPack) or the motor. 2 Using the vehicle or the rechargeable lithium-ion battery (KTM PowerPack) in a condition without proper maintenance. 3 Using the vehicle or the rechargeable lithium-ion battery (KTM PowerPack) beyond its defined use.

  • Page 13: Fall Or Accident

    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 14: Environment

    When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the applica- ble laws and regulations in your country. When disposing of the lithium-ion battery (KTM PowerPack) and the 12 V battery, comply with the laws and regu- lations of the respective country.

  • Page 15: Important Notes 3

    Manufacturer and implied 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 the KTM Dealer.net, otherwise any warranty coverage will become void.

  • Page 16: System Voltage

    The 12 V battery is located at the rear, under the seat. 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 17: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) F01657-10 Front brake lever ( p. 19) Rear brake lever ( p. 19) Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 21) Steering lock ( p.

  • Page 18: View Of Vehicle, Rear Right (Example)

    23) Fork compression adjuster Horn button ( p. 20) Light switch ( p. 20) Turn signal switch ( p. 21) Main switch ( p. 19) Start button ( p. 20) Throttle grip ( p. 19) Fork rebound adjustment KTM PowerPack...

  • Page 19: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification 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 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key.

  • Page 20: Fork Part Number

    Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the motor side. H02222-10 Battery identification number The battery identification number (BIN) is stamped under the handle of the KTM PowerPack. A00167-10...

  • Page 21: Controls 6

    CONTROLS 6 Front brake lever Front brake lever is fitted on the right side of the handlebar. A00173-10 Rear brake lever Rear brake lever is fitted on the left side of the handlebar. A00174-10 Throttle grip The throttle grip is fitted on the right side of the handlebar. A00175-10 Main switch The main switch...

  • Page 22: Start Button

    6 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 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 23: Turn Signal Switch

    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. A00169-10 Possible states Ignition off – In this position, the electric circuit of the 12-V battery is interrupted and the vehicle cannot be activated.

  • Page 24: Steering Lock

    6 CONTROLS 6.11 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and there- fore riding, is no longer possible. A00168-10 6.12 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 25: Display 7

    DISPLAY 7 Multifunction display 7.1.1 Multifunction display The multifunction display is attached in front of the seat. Overview of the multifunction display Driving mode tip switch ( p. 23) Driving mode display ( p. 24) Malfunction indicator lamp ( p. 24) Charge level indicator ( p.

  • Page 26: Driving Mode Display

    7 DISPLAY 7.1.3 Driving mode display Red driving mode displays with the numbers 1, 2 or 3 show the driving mode selected. Three different driving modes are available. The driving modes determine how the vehicle reacts to throttle grip operation. The figures only show approximate values for illustrative purposes, and do not describe the actual reaction.

  • Page 27: Power Reduction

    9 °C and 50 % of power at temperatures 402363-10 of less than 0 °C. 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 28: Overview

    7 DISPLAY Overview 7.2.1 Overview of indicator lamps Possible states The high beam indicator lamp lights up blue – The high beam is switched on. Turn signal indicator lamp flashes green – The turn signal is switched on. F01195-01...

  • Page 29: Combination Instrument 8

    COMBINATION INSTRUMENT 8 Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. A00202-10 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 30: Setting The Combination Instrument

    8 COMBINATION INSTRUMENT – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 31: Setting The Clock

    COMBINATION INSTRUMENT 8 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust the hour display with the button and/or button –...

  • Page 32: Display Mode Speed (Speed)

    8 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 33: Adjusting The Unit Of Measurement

    COMBINATION INSTRUMENT 8 Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 34: Display Mode Speed/Clk (Time)

    8 COMBINATION INSTRUMENT 8.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 35: Viewing The Lap Time

    COMBINATION INSTRUMENT 8 Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 36: Display Mode Speed/Tr1 (Trip Master 1)

    8 COMBINATION INSTRUMENT 8.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 37: Display Mode Speed/A1 (Average Speed 1)

    COMBINATION INSTRUMENT 8 Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 38: Display Mode Speed/S1 (Stop Watch 1)

    8 COMBINATION INSTRUMENT Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 8.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 39: Table Of Functions

    COMBINATION INSTRUMENT 8 8.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 40: Table Of Conditions And Menu Activation

    8 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Adjusting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • Page 41: Preparing For Use 9

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

  • Page 42: 10 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 it is being operated. – Check the throttle grip, main switch, KTM PowerPack, multi- function display, and electric motor for external damage. –...
  • Page 43 RIDING INSTRUCTIONS 10 – Push main switch into position The vehicle is in standby. A00175-13 Optional: – Press and hold driving mode tip switch for at least one second. Driving mode is activated when the tip switch is let go. 402133-11 –...

  • Page 44: Starting Off

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 45: Stopping, Parking

    RIDING INSTRUCTIONS 10 10.6 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 46: 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 47: Service Schedule 11

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 48: Recommended Work

    Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make the service entry in KTM Dealer.net and in the Service & Manufacturer Warranty Book- let. ○ One-time interval ● Periodic interval 11.3...

  • Page 49: Tuning The Chassis 12

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow 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 50: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow 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 51: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 52: Measuring The Rear Wheel Dimension Unloaded

    Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping during rebound of the shock absorber. Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 12.6 Measuring the rear wheel dimension unloaded Preparatory work –...

  • Page 53: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 12 12.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 50) – Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed point again.

  • Page 54: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow 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 spring length.

  • Page 55: Adjusting The Riding Sag

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 56: Adjusting The Compression Damping Of The Fork

    12 TUNING THE CHASSIS 12.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 57: Handlebar Position

    Change the handlebar if the handlebar is damaged or bent. Preparatory work – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71)
  • Page 58 Position the handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the gap widths are even. Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69)

  • Page 59: Service Work On The Chassis 13

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Use the motor guard underneath the motor to raise the vehicle.

  • Page 60: Bleeding The Fork Legs

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 61: Installing The Fork Protector

    – Position the brake line, wiring harness, and clamp. Mount and tighten screws F01666-11 Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 13.6 Cleaning the dust boots of the fork legs Preparatory work –...

  • Page 62: Removing The Fork Legs

    – Install the fork protector. ( p. 59) – Remove the motorcycle from the lift stand. ( p. 57) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 13.7 Removing the fork legs Preparatory work –...

  • Page 63: Installing The Fork Legs

    – Install the front wheel. p. 91) – Install the headlight mask with the headlight. ( p. 102) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) – Check the headlight setting. ( p. 105) 13.9...

  • Page 64: Installing The Lower Triple Clamp

    13 SERVICE WORK ON THE CHASSIS Main work – Open holder and detach the wiring harness and brake line. A00204-10 – 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 65 SERVICE WORK ON THE CHASSIS 13 – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Position the rear wheel brake line and wiring harness. C00834-10 – Position the fork legs. Bleeder screws face forwards.

  • Page 66: Checking Steering Head Bearing Play

    105) 13.11 Checking steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 67: Adjusting Steering Head Bearing Play

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 68: Greasing The Steering Head Bearing

    – Check steering head bearing play. p. 64) – Remove the motorcycle from the lift stand. ( p. 57) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 13.13 Greasing the steering head bearing –...

  • Page 69: Installing Front Fender

    10 Nm (7.4 lbf ft) chassis E00985-10 Finishing work – Install the headlight mask with the headlight. ( p. 102) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) – Check the headlight setting. ( p. 105)

  • Page 70: Removing The Shock Absorber

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 71: Folding The Seat Up

    Removing the spoiler Preparatory work – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Remove screws F01211-10...

  • Page 72: Installing The Spoiler

    Mount and tighten screws Guideline Screw, front spoiler EJOT PT ® 3 Nm (2.2 lbf ft) K60x30‑Z – Repeat these steps on the opposite side. F01211-11 Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69)

  • Page 73: Mounting The Protection Cap

    SERVICE WORK ON THE CHASSIS 13 13.22 Mounting the protection cap Note Material damage Components damaged or destroyed by water or dirt. – Mount the protection cap after you have removed the KTM PowerPack. Preparatory work – Deactivate the vehicle. ( p. 43) –...

  • Page 74: Checking For Chain Dirt Accumulation

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. (...

  • Page 75: Checking The Chain Tension

    Off-road chain spray ( p. 139) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. 57) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 13.27 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.

  • Page 76: Adjusting The Chain Tension

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 77: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.
  • Page 78 13 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 79: Checking The Frame

    – Change the frame. Info A frame that has been damaged due to a mechanical impact must be replaced. Repair of 402151-01 the frame is not authorized by KTM. Finishing work – Install the KTM PowerPack. ( p. 108) –...

  • Page 80: Checking The Rubber Grip

    A damaged link fork must always be replaced. Repairing the link fork is not authorized by KTM. 402152-01 Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 13.32 Checking the rubber grip –...

  • Page 81: Brake System 14

    Do not make any adjustments while riding. 14.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 82: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir attached to the right of the han- dlebar to a horizontal position.

  • Page 83: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Unsuitable brake fluid damages the brake system.

  • Page 84: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for lining thickness ≥...
  • Page 85 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 86 14 BRAKE SYSTEM Main work – Move the brake fluid reservoir attached to the right of the han- dlebar to a horizontal position. – Remove screws – Take off cover with membrane A00200-11 – Remove screws with spacers. – Remove the cable tie. –...

  • Page 87: Checking The Free Travel Of The Rear Brake Lever

    A00200-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 14.8 Checking the free travel of the rear brake lever Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 88: Checking The Rear Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir attached to the left of the han- dlebar to a horizontal position.
  • Page 89 – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Check the rear brake linings. ( p. 88) Main work –...

  • Page 90: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for lining thickness ≥...
  • Page 91 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 92 Position the cover with the membrane. Mount and tighten the screws. A00201-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69)

  • Page 93: Wheels, Tires 15

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. ( p.

  • Page 94: Removing The Rear Wheel

    The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 15.3 Removing the rear wheel Preparatory work –...

  • Page 95: Installing The Rear Wheel

    WHEELS, TIRES 15 Main work – Remove nut – Remove chain adjuster Info Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.
  • Page 96 F01681-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 57) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69)

  • Page 97: Checking The Tire Condition

    The first two digits indicate the week of manufacture and the last two digits 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 98: Checking The Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) Preparatory work –...
  • Page 99 WHEELS, TIRES 15 Guideline Spoke nipple M4.5 6 Nm (4.4 lbf ft) Torque wrench kit (58429094000) Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69)

  • Page 100: 16 Electrical System

    16 ELECTRICAL SYSTEM 16.1 Removing the 12 V battery Warning Risk of injury Battery gases cause serious chemical burns. – Keep the 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery gases. –...

  • Page 101: Charging The 12 V Battery

    The 12 V battery is maintenance-free. The acid level does not have to be checked. Info The 12 V battery is recharged by the KTM PowerPack when operating the vehicle. When the KTM PowerPack is recharged in the vehicle, then the 12 V battery is also recharged. Preparatory work –...

  • Page 102: Changing The Fuses Of Individual Power Consumers

    Preparatory work – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Detach catches and open the fuse box cover.

  • Page 103: Removing The Headlight Mask With The Headlight

    – 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. 108) – Lock the seat. ( p. 69) 16.5 Removing the headlight mask with the headlight Preparatory work –...

  • Page 104: Installing The Headlight Mask With The Headlight

    16 ELECTRICAL SYSTEM Main work – Detach the brake line and wiring harness – Loosen rubber straps . Slide the headlight mask up and swing it forward. A00196-10 – Disconnect plug-in connector of the turn signal relay, plug- in connectors of the turn signals, plug-in connector the headlight and plug-in connector of the ignition lock.

  • Page 105: Changing The Headlight Bulb

    Position the headlight mask and secure it with rubber straps The holding lugs on the headlight mask engage in the fender. A00196-12 Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) – Check the headlight setting. ( p.

  • Page 106: Changing The Turn Signal Bulb

    Insert the bulb socket of the position light into the reflector. Finishing work – Install the headlight mask with the headlight. ( p. 102) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) –...

  • Page 107: Checking The Headlight Setting

    – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) –...

  • Page 108: Changing The Combination Instrument Battery

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Remove the headlight mask with the headlight. ( p.

  • Page 109: Ktm Powerpack, Battery Charger 17

    Work which has not been described and explained may only be performed by correspondingly trained KTM specialists. (Your authorized KTM workshop will be glad to help.) – Do not open the electric motor or the KTM PowerPack. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard A lithium-ion battery (KTM PowerPack) contains components and elements that are...

  • Page 110: Installing The Ktm Powerpack

    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 bat- tery discharge socket on the KTM PowerPack are clean. – Check the battery discharge plug form ring.

  • Page 111: Overview Of The Ktm Powerpack 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 112: Checking Residual Current Protection Switch

    17 KTM POWERPACK, BATTERY CHARGER Warning Risk of injury There is a risk of electric shock if the battery charger or the cables have been manipulated or damaged. The battery charger does not contain any parts which require maintenance. – Do not modify the battery charger or the cables.

  • Page 113: Charging The Ktm Powerpack

    If the vehicle is activated while the vehicle is being charged with the KTM PowerPack installed, the vehi- cle switches to the fault state. The KTM PowerPack will continue to be recharged, however the 12 V bat- tery will stop recharging.
  • Page 114 Switch on the battery charger using switch Charging starts automatically. The status indicator flashes during the charging process. C00769-10 – Monitor the charging level of the KTM PowerPack using the LEDs. LED 1: 20 % LED 2: 40 % C00770-10...

  • Page 115: Charging The Ktm Powerpack In The Storage Charging Mode

    KTM workshop will be glad to help.) Info 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 bat- tery charger stops charging.
  • Page 116 Charging starts automatically. The status indicator flashes during the charging process. C00769-10 – Monitor the charging level of the KTM PowerPack using the LEDs. LED 1: 20% LED 2: 40 % After the charging process is completed to a level of 50%, LEDs 1 and 2 light up and the status indicator goes out.

  • Page 117: 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 118 Position loop around the right carry handle attachment. M00744-10 – 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)

  • Page 119: Cooling System 18

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) – Raise the motorcycle with a lift stand. (...

  • Page 120: Checking The Coolant Level

    137) – Mount the radiator cap. Finishing work – Remove the motorcycle from the lift stand. ( p. 57) – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 18.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

  • Page 121: Draining The Coolant

    Preparatory work – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Position the motorcycle upright.

  • Page 122: Refilling With Coolant

    Preparatory work – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Ensure that the screws are tightened.

  • Page 123: Tuning The Engine 19

    TUNING THE ENGINE 19 19.1 Selecting the driving mode Condition Alternative 1 The motorcycle is stationary. The motorcycle is ready for operation. Alternative 2 The motorcycle is stationary. The motorcycle is ready to drive. Alternative 3 The motorcycle is moving. ≤...

  • Page 124: 20 Service Work On The Engine

    – Deactivate the vehicle. ( p. 43) – Fold the seat up. ( p. 69) – Remove the KTM PowerPack. ( p. 107) – Mount the protection cap. ( p. 71) Main work – Place an appropriate container under the engine.
  • Page 125 8 Nm (5.9 lbf ft) – Stand the motorcycle upright. C00745-11 Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) – Go for a short test ride and check the motor has no leaks.

  • Page 126: 21 Cleaning, Care

    The high pressure allows water to penetrate electrical components, plugs, bearings, etc. This results in compo- nents 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 127: Checks And Maintenance Steps For Winter Operation

    ( p. 139) – Oil the steering lock. Universal oil spray ( p. 139) Finishing work – Install the KTM PowerPack. ( p. 108) – Lock the seat. ( p. 69) 21.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, salt can be expected on the roads.

  • Page 128: 22 Storage

    Have service work, repairs or conversions performed outside the motorcycling season, if possible. This allows you to avoid long waiting periods when the next season starts. – Discharge the KTM PowerPack to a charging level of 50%. – Check all motorcycle parts for function and wear.

  • Page 129: Preparing For Use After 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 130: 23 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 402136-10 will be happy to help you.
  • Page 131 Blink code 52 on the vehicle Fault in the moisture monitor Switch the main switch off and on. – Blink code 53 on the vehicle Fault in the KTM PowerPack Switch the main switch off and on. relay – Blink code 54 on the vehicle...

  • Page 132: Troubleshooting Of The Battery Charger

    If a fault is not eliminated by the measures specified here, 402156-10 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 sec- onds.

  • Page 133: Troubleshooting Of The Ktm Powerpack When Connected To The Battery Charger

    TROUBLESHOOTING 23 23.3 Troubleshooting of the KTM PowerPack when connected to the battery charger The faults are indicated by LED on the battery charger. All of the following blink codes are displayed on the charger and refer to the KTM PowerPack.

  • Page 134: 24 Technical Data

    24 TECHNICAL DATA 24.1 Engine 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 24.2 Engine tightening torques Coolant drain plug 10 Nm (7.4 lbf ft) Oil seal plug 8 Nm (5.9 lbf ft) Oil drain plug with magnet...

  • Page 135: Electrical System

    1,418 ± 10 mm (55.83 ± 0.39 in) Ground clearance, unloaded 340 mm (13.39 in) Seat height, unloaded 910 mm (35.83 in) Homologated weight with KTM PowerPack approx. 111 kg (245 lb.) Maximum permissible front axle load 110 kg (243 lb.) Maximum permissible rear axle load 170 kg (375 lb.)

  • Page 136: Tires

    4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 24.7 Fork Fork article number 05.18.8S.40 WP SuspensionXplor 43...

  • Page 137: Chassis Tightening Torques

    Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring 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) Screw for spoiler attachment 5 Nm (3.7 lbf ft)
  • Page 138 24 TECHNICAL DATA Screw, subframe 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, top steering stem 17 Nm (12.5 lbf ft) Loctite ® 243™ Screw, top triple clamp 22 Nm (16.2 lbf ft) Motor bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 139: Substances 25

    SUBSTANCES 25 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 corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 140 25 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 140) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 141: Auxiliary Substances 26

    AUXILIARY SUBSTANCES 26 Chain cleaner Recommended supplier MOTOREX ® – Chain Clean High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Off-road chain spray Recommended supplier MOTOREX...

  • Page 142: 27 Standards

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

  • Page 143: Index Of Special Terms 28

    INDEX OF SPECIAL TERMS 28 Battery identification number Serial number of the KTM PowerPack; this is linked to the vehicle's identification number...

  • Page 144: 29 List Of Abbreviations

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

  • Page 145: List Of Symbols 30

    LIST OF SYMBOLS 30 30.1 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. The malfunction indicator lamp flashes – A error is present in the vehicle electronic system. 30.2 Green and blue symbols Green and blue symbols reflect information.

  • Page 146: Index

    INDEX Charging socket protection cap INDEX changing ......115 12-V battery Combination instrument charging ......99 combination instrument battery, changing .
  • Page 147 Key number ......17 KTM PowerPack Rear brake lever ......19 battery identification number (BIN) .
  • Page 148 Safe operation ......10 of KTM PowerPack on battery charger ..131 Safety advice .
  • Page 149 *3213862en* 3213862en 07/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
  • Page 150 *3213984en* RESCUE CARD KTM Freeride E 2019 112 European emergency number Technical emergency number ....http://www.ktm.com/rescuecard Model example Main switch Ignition lock High-voltage cabling...
  • Page 151 – The high-voltage components in the vehicle are identified by yellow warning labels. – The high-voltage cables in the motor housing and in the KTM PowerPack can be identified by the orange color of their insulation. – Before beginning work on the vehicle, switch off main switch...

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