KTM Freeride E-XC 2018 Manual

SETUP INSTRUCTIONS 2018

Freeride E‑XC

Art. no. 3213744en

INTRODUCTION

*3213744en*

3213744en

06/2017

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make

changes in the interest of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop

are not specified here. It is assumed that the work will be performed by a fully trained mechanic with the corre-

sponding HV training.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete

technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice

and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular

model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,

misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the

regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assur-

ance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

Freeride E‑XC EU (F3001R1)

1 MEANS OF REPRESENTATION

1.1 Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies work requiring expert knowledge and technical understanding. In the interest of your

own safety, only have these jobs performed by correspondingly trained KTM technical person-

nel.

All work identified by this symbol requires a level 1 qualification for high-voltage systems. Only

this qualification authorizes you to perform non-electro-technical work on a vehicle or on units

with a high-voltage system.

All work identified by this symbol requires a level 2 qualification for high-voltage systems.

Only this qualification authorizes you to de-energize the electrical system and perform

electro-technical work in a de-energized state.

All work identified by this symbol requires a level 3 qualification for high-voltage systems. Only

this qualification authorizes you to perform electro-technical work under voltage.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1 MEANS OF REPRESENTATION

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

2 SAFETY ADVICE

2.1 Work rules

The KTM PowerPack does not contain any parts that require maintenance. Do not open the KTM PowerPack

under any circumstances.

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered

using the number in parentheses. Example: transmission shaft holder (70029032000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock

washers) must be replaced by new parts.

In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be fol-

lowed.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged

or worn parts.

After you complete the repair or service work, check the operating safety of the vehicle.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual

carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.

Info

The vehicle has various information and warning labels at prominent locations. Do not remove informa-

tion/warning labels. If they are missing, you or others may not recognize dangers and may therefore be

injured.

2.3 Degrees of risk and symbols

Warning

Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are

not taken.

Warning

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Operating and auxiliary substances

Use the operating and auxiliary substances (such as oils and lubricants) specified in the Owner's Manual.

2.5 Fire hazard

Warning

Fire hazard Damaged rechargeable lithium-ion batteries (KTM PowerPacks) present a fire hazard.

Massive mechanical damage may cause an internal cell short circuit and cause the battery to self-ignite.

–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.

2 SAFETY ADVICE

However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a

rechargeable lithium-ion battery is on fire.

3 SETUP

3.1 Unpacking and setting up the vehicle

C00858-10

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup,

leave the protective film on the vehicle until you have

finished.

–Remove the separate enclosure and unpack it. Check that the

scope of supply is complete using the enclosed packing list.

–To be in compliance with the homologation of the vehicle,

mount all of the parts in the separate enclosure when assem-

bling the vehicle.

Info

It is not necessary to mount all of the parts in the sepa-

rate enclosure for the vehicle to operate correctly. How-

ever, homologation will not apply if not all parts from

the separate enclosure are mounted.

–Remove the KTM PowerPack. ( p. 24)

–Have a lift stand available.

Lift stand (78129955100)

–Carefully loosen and remove the tension belt of the footrest

bracket.

Info

An assistant prevents the motorcycle from falling over.

402050-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

C00761-10

–Remove screws 1. Take off the handlebar clamps.

–Remove screws 2. Take off the handlebar supports.

–Place the handlebar supports in the required position. Mount

and tighten screws 2.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

3 SETUP

C00860-01

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the screws

evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Info

The markings on the handlebar should be at the center

of the handlebar clamps.

Keep the gap widths equal when tightening.

C00867-01

–Position the front fender and mount and tighten the screws.

Guideline

Remaining screws,

chassis

M6 10 Nm (7.4 lbf ft)

M00696-01

–Release the axle clamp screws and remove the wheel spindle.

–Install the front wheel. ( p. 16)

C00863-01

–Position the controls on the right half of the handlebar.

3 SETUP

C00864-01

–Position the controls on the left half of the handlebar.

402390-01

–Mount the turn signal switch and connect the plug-in connec-

tor on the wiring harness.

C00865-01

–Join all plug-in connectors to the plug-in holder.

Info

Make sure the cables and wiring are positioned cor-

rectly.

C00866-10

–Position turn signal indicator lamp 3.

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