KTM Freeride E-XC 2018 Owner's Manual
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KTM Freeride E-XC 2018 Owner's Manual

KTM Freeride E-XC 2018 Owner's Manual

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OWNER'S MANUAL
2018
Freeride E-XC
Art. no. 3213653en

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Summary of Contents for KTM Freeride E-XC 2018

  • Page 1 OWNER'S MANUAL 2018 Freeride E-XC Art. no. 3213653en...
  • 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 your new vehicle! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    Stopping, parking......36 Battery identification number.... 18 Deactivating the vehicle....37 Transporting the vehicle ....37 CONTROLS..........19 Transporting the KTM PowerPack ..38 Front brake lever......19 10 SERVICE SCHEDULE ........39 Rear brake lever....... 19 Throttle grip ........19 10.1...
  • Page 5 TABLE OF CONTENTS 11 TUNING THE CHASSIS ....... 41 12.19 Locking the seat ......63 12.20 Removing the spoiler......63 11.1 Checking the basic chassis setting 12.21 Installing the spoiler......64 with the rider's weight ...... 41 12.22 Mounting the covering cap ....65 11.2 Compression damping of the shock 12.23 Removing the covering cap ....
  • Page 6 Chassis ......... 127 15.11 Changing the speedometer battery ... 100 23.5 Electrical system......128 23.6 Tires ..........129 16 KTM POWERPACK, BATTERY CHARGER ..102 23.7 Fork..........129 16.1 Removing the KTM PowerPack ..102 23.8 Shock absorber ......130 16.2...

  • 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! 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 KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The vehicle is only authorized for operation on public roads in the homologated version.

  • Page 9: Safety Instructions And Warning Labels

    2 SAFETY ADVICE Safety instructions and warning labels 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.
  • Page 10 2 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...

  • Page 11: Tampering Warning

    2 SAFETY ADVICE High-voltage components and electric shock, see the Owner's Manual C00842-01 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:...

  • Page 12: Safe Operation

    2 SAFETY ADVICE 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: Protective Clothing

    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 14: Owner's Manual

    Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat- tery (KTM PowerPack) has occurred. There is no particular fire hazard for this vehicle when the rechargeable lithium-ion battery (KTM PowerPack) is intact. However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a...

  • Page 15: Important Notes

    3 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.

  • 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 View of vehicle, front left (example) A00125-10 Front brake lever ( p. 19) Rear brake lever ( p. 19) Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 21)

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

    23) 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 Fork compression adjustment KTM PowerPack...

  • Page 19: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing 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.

  • Page 20: Shock Absorber Article Number

    The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10 Battery identification number The battery identification number (BIN) is stamped under the handle of the KTM PowerPack. C00771-10...

  • Page 21: Controls

    6 CONTROLS Front brake lever The front brake handle is fitted on the right side of the handle- bar. C00791-10 Rear brake lever The rear brake lever is fitted on the left side of the handlebar. C00792-10 Throttle grip The throttle grip is fitted on the right side of the handlebar.

  • 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. C00825-10 Possible states Ignition off –...

  • 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. C00824-10 6.12 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over.

  • Page 25: Display

    7 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. 23) Driving mode display ( p. 24) Electric motor 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

    The selected driving mode flashes slowly and the charge level indicator lights up red or flashes red: – The charge state of the KTM PowerPack is below 20%. Vehi- cle power is reduced. Switch off the vehicle and charge the KTM PowerPack. Overview 7.2.1...

  • Page 29: 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 30: Setting The Kilometers Or Miles

    7 DISPLAY – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. – Set the service. Guideline One-time service after Service every 20 h Shortening the service interval 401913-01 – Press the left button. The value decreases.

  • Page 31: Setting The Service Display

    7 DISPLAY – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock.

  • Page 32: Speed, Time, And Dst Distance 1

    7 DISPLAY 7.3.8 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedome- ter. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two recharging cycles.

  • Page 33: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    7 DISPLAY 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 on the combination instrument. AVG shows the average speed since the last reset. ART shows the operating hours. ODO shows the total distance covered.

  • Page 34: 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 35 8 PREPARING FOR USE Guideline Maximum permissible overall weight 280 kg (617 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.)

  • Page 36: 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, multifunction display, and electric motor for external damage. –...
  • Page 37 9 RIDING INSTRUCTIONS – Push the main switch into position The vehicle is ready for operation. C00793-12 Optional: – Press and hold the map-select tip switch for at least one second. Driving mode is activated when the switch is let go. 402133-11 –...

  • Page 38: 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 39: Deactivating The Vehicle

    9 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...

  • Page 40: Transporting The Ktm Powerpack

    – 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

    Every 20 operating hours when used for motorsports Once after 1 operating hour ○ ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● Check that the electrical system is functioning properly. ● ●...

  • Page 42: Recommended Work

    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 Manufacturer Warranty Booklet. ○ One-time interval ● Periodic interval 10.3...

  • Page 43: Tuning The Chassis

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 44: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 45: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 46: Measuring Rear Wheel Sag 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. 103) – Lock the seat. ( p. 63) 11.6 Measuring rear wheel sag unloaded Preparatory work –...

  • Page 47: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 44) – Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed point again.

  • Page 48: 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 length of the spring.

  • Page 49: Adjusting The Riding Sag

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 50: Adjusting The Compression Damping Of The Fork

    Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) Main work – Remove protection caps –...

  • Page 51: Adjusting The Rebound Damping Of The Fork

    Change the handlebar if the handlebar is damaged or bent. Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65)
  • Page 52 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. 103) – Lock the seat. ( p. 63)

  • Page 53: Service Work On The Chassis

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) Main work – Use the motor guard underneath the motor to raise the vehicle.

  • Page 54: Bleeding The Fork Legs

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 55: Removing The Fork Legs

    – Install the fork protector. ( p. 55) – Remove the motorcycle from the lift stand. ( p. 51) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 12.5 Removing the fork legs Preparatory work –...

  • Page 56: Installing The Fork Legs

    – Install the front wheel. p. 86) – Refit the headlight mask with the headlight. ( p. 96) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) – Check the headlight setting. ( p. 99) 12.7...

  • Page 57: Installing The Fork Protector

    Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws A00126-11 Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • Page 58: Removing The Lower Triple Clamp

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 59: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 134) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 60 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head C00831-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite 243™ ® steering stem C00830-10 –...

  • Page 61: Checking The Play Of The Steering Head

    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.) 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: Adjusting The Steering Head Bearing Play

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 63: Removing Front Fender

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Remove the headlight mask with the headlight. ( p.

  • Page 64: Installing The Shock Absorber

    Guideline Screw, upper 45 Nm (33.2 lbf ft) Loctite ® 243™ subframe Finishing work – Remove the motorcycle from the lift stand. ( p. 51) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • 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. 102) – Mount the covering cap. ( p. 65) Main work – Remove screws C00763-10...

  • Page 66: Installing The Spoiler

    Mount and tighten screw – Mount and tighten screw C00764-11 – Mount and tighten screws – Repeat the operation on the opposite side. C00763-11 Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • Page 67: Mounting The Covering Cap

    12 SERVICE WORK ON THE CHASSIS 12.22 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) –...

  • Page 68: Checking The Battery Discharge Plug Form Ring

    12 SERVICE WORK ON THE CHASSIS 12.24 Checking the battery discharge plug form ring Condition The KTM PowerPack has been removed. The covering cap has been removed. – Check the battery discharge plug form ring on the electric motor. »...

  • Page 69: Checking The Chain Tension

    Off-road chain spray ( p. 134) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. 51) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 12.27 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.

  • Page 70: Adjusting The Chain Tension

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 71: 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. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.
  • Page 72 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain sliding guard: – Change the chain sliding guard. –...

  • Page 73: 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. 103) –...

  • Page 74: Checking The Rubber Grip

    Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by 402152-01 KTM. Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 12.32 Checking the rubber grip –...

  • Page 75: Brake System

    Do not make any adjustments while riding. 13.3 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 76: Checking The Brake Fluid Level Of The Front Brake

    – 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 77: 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 78: 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 79 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 80 13 BRAKE SYSTEM Main work – Move the brake fluid reservoir attached to the right of the han- dlebar to a horizontal position. – Remove screws – Remove cover with membrane A00158-11 – Remove screws and spacers. – Remove the cable tie(s). –...

  • Page 81: Checking The Free Travel Of The Rear Brake Lever

    A00158-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 13.8 Checking the free travel of the rear brake lever Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 82: 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 83 – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Check the rear brake linings. ( p. 82) Main work –...

  • Page 84: 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 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 Position the cover with the membrane. Mount and tighten the screws. A00132-12 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • Page 87: Wheels, Tires

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. ( p.

  • Page 88: Installing The Front Wheel

    The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 14.3 Removing the rear wheel Preparatory work –...

  • Page 89: Installing The Rear Wheel

    14 WHEELS, TIRES 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 90 C00707-11 Finishing work – Remove the motorcycle from the lift stand. ( p. 51) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • Page 91: 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 92: 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 93 14 WHEELS, TIRES Guideline Spoke nipple M4.5 6 Nm (4.4 lbf ft) Torque wrench set (58429094000) Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63)

  • Page 94: Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the 12 V battery Warning Risk of injury Battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery gases. –...

  • Page 95: Charging The 12 V Battery

    The 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 96: 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. 102) – Mount the covering cap. ( p. 65) Main work – Detach catches and open the fuse box cover.

  • Page 97: 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. 103) – Lock the seat. ( p. 63) 15.5 Removing the headlight mask with the headlight Preparatory work –...

  • Page 98: Refitting The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Main work – Switch off all power consumers. – Detach the brake line and wiring harness – Release rubber bands . Slide the headlight mask up and swing it forward. C00811-10 – Disconnect plug-in connectors of turn signals, headlight and the ignition lock.

  • Page 99: Changing The Headlight Bulb

    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. 103) – Lock the seat. ( p. 63) – Check the headlight setting. ( p.

  • Page 100: Changing The Turn Signal Bulb (Option: Turn Signal, Round)

    Insert the bulb socket of the parking light into the reflector. Finishing work – Refit the headlight mask with the headlight. ( p. 96) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) –...

  • Page 101: Checking The Headlight Setting

    Position the diffuser. – Insert the screw and first turn it counterclockwise until it engages in the thread. Tighten the screw slightly. Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) –...

  • Page 102: Adjusting The Headlight Range

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Remove the headlight mask with the headlight. ( p.
  • Page 103 Mount and tighten the screws with washers. C00821-10 Finishing work – Refit the headlight mask with the headlight. ( p. 96) – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) – Check the headlight setting. ( p.

  • Page 104: Ktm Powerpack, Battery Charger

    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.) Warning Environmental hazard A lithium-ion battery (KTM PowerPack) contains components and elements that are...

  • Page 105: 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 106: Overview Of The Ktm Powerpack Battery Charger

    16 KTM POWERPACK, BATTERY CHARGER 16.3 Overview of the KTM PowerPack battery charger 402153-10 Residual current protection switch "On" charger switch "Off" charger switch Battery charger Charging mode switch Charge level indicator Status indicator LED for KTM PowerPack fault LED for charger fault 16.4...
  • Page 107 16 KTM POWERPACK, 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 108: Checking Residual Current Protection Switch

    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 109 16 KTM POWERPACK, BATTERY CHARGER Info When the left LED in the charge level indicator on the battery charger flashes, then the KTM PowerPack is ready for use. However, full capacity is not yet available. To guarantee the maximum capacity of the KTM PowerPack, discharge the KTM PowerPack completely every 20 charging cycles and then recharge it completely.

  • Page 110: Charging The Ktm Powerpack In The Storage Charging Mode

    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 % LED 3: 60 % LED 4: 80 % LED 5 flashes beginning with approx.
  • Page 111 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 112: 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 113 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 114: Cooling System

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) – Raise the motorcycle with a lift stand. (...

  • Page 115: Checking The Coolant Level

    132) – Mount the radiator cap. Finishing work – Remove the motorcycle from the lift stand. ( p. 51) – Install the KTM PowerPack. ( p. 103) – 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 116: Draining The Coolant

    Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) Main work – Position the motorcycle upright.

  • Page 117: Refilling With Coolant

    Preparatory work – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) Main work – Ensure that the screws are tightened.

  • Page 118: Tuning The Motor

    18 TUNING THE MOTOR 18.1 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 119: Service Work On The Motor

    – Deactivate the vehicle. ( p. 37) – Fold the seat up. ( p. 63) – Remove the KTM PowerPack. ( p. 102) – Mount the covering cap. ( p. 65) Main work – Place a suitable container under the motor.
  • Page 120 8 Nm (5.9 lbf ft) – Stand the motorcycle upright. C00745-11 Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) – Go for a short test ride and check the motor has no leaks.

  • Page 121: 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 122: Checks And Maintenance Steps For Winter Operation

    Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 134) Finishing work – Install the KTM PowerPack. ( p. 103) – Lock the seat. ( p. 63) 20.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads.

  • Page 123: Storage

    Have maintenance 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 124: 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 125: 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 126 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 127: 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 128: Troubleshooting Of The Ktm Powerpack When Connected To The Battery Charger

    22 TROUBLESHOOTING 22.3 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 129: Technical Data

    23 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 130: 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. 110 kg (243 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.)

  • Page 131: Tires

    2.75 - 21 M/C 45M TT 120/90 - 18 M/C 65R TT MAXXIS TRIALMAXX MAXXIS MAXX ENDURO The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 05.18.7N.41 Fork...

  • Page 132: Shock Absorber

    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, front brake disc 14 Nm (10.3 lbf ft)
  • Page 133 23 TECHNICAL DATA KTM PowerPack attachment 15 Nm (11.1 lbf ft) Loctite ® 243™ Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Nut, rim lock 10 Nm (7.4 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft)

  • Page 134: Substances

    24 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 corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 135 24 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 135) (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 136: Auxiliary Substances

    25 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...

  • Page 137: Standards

    26 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 138: Index Of Special Terms

    27 INDEX OF SPECIAL TERMS Battery identification number Serial number of the KTM PowerPack; this is linked to the vehicle's chassis number Electric motor control lamp (Mal- Indicator lamp that supports vehicle diagnostics function Indicator Lamp) through flash codes...

  • Page 139: List Of Abbreviations

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

  • Page 140: List Of Symbols

    29 LIST 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 141: Index

    INDEX checking ......67 INDEX Charge level indicator ....24 12 V battery Charging socket protection cap charging .
  • Page 142 ....79 Rear sprocket KTM PowerPack checking ......69 battery identification number (BIN) .
  • Page 143 ......62 of KTM PowerPack on battery charger ..126 removing .
  • Page 144 *3213653en* 3213653en 06/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
  • Page 145 *3213740en* RESCUE CARD KTM Freeride E 2018 112 European emergency number Technical emergency number ....http://www.ktm.com/rescuecard Model example Main switch Ignition lock High-voltage cabling...
  • Page 146 – 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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