SETUP INSTRUCTIONS 2018
Freeride E‑XC
Art. no. 3213744en
INTRODUCTION
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 corresponding 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.
© 2017 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
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 assurance 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)
*3213744en*
3213744en
06/2017
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 personnel.
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.
2
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
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
Indicates a protected name.
are explained in the glossary.
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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 followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
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 information/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.
4
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.
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3 SETUP
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3.1 Unpacking and setting up the vehicle
– Remove the box and the plastic packaging.
– Remove the separate enclosure and unpack it. Check that the
C00858-10
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 assembling the vehicle.
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.
Info
It is not necessary to mount all of the parts in the separate enclosure for the vehicle to operate correctly. However, homologation will not apply if not all parts from
the separate enclosure are mounted.
402050-01
– 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.
– Together with an assistant, take the vehicle off the pallet.
– Position the vehicle on a lift stand.
– Check the vehicle for transport damage.
–
Remove screws1. Take off the handlebar clamps.
–
Remove screws2. Take off the handlebar supports.
– Place the handlebar supports in the required position. Mount
and tighten screws2.
Guideline
Screw, handlebar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
6
C00761-10
Info
Position the left and right handlebar supports evenly.
C00860-01
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
M8 20 Nm (14.8 lbf ft)
clamp
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the gap widths equal when tightening.
– Position the front fender and mount and tighten the screws.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3 SETUP
C00867-01
M00696-01
C00863-01
– Release the axle clamp screws and remove the wheel spindle.
– Install the front wheel. ( p. 16)
– Position the controls on the right half of the handlebar.
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3 SETUP
– Position the controls on the left half of the handlebar.
C00864-01
– Mount the turn signal switch and connect the plug-in connec-
tor on the wiring harness.
402390-01
C00865-01
C00866-10
– Join all plug-in connectors to the plug-in holder.
Info
Make sure the cables and wiring are positioned correctly.
–
Position turn signal indicator lamp3.
8
M00697-01
C00868-10
– Mount the handlebar cushion.
– Take off the electrical compartment.
–
Connect turn signal relay4.
– Route the wiring harness for the rear turn signal and license
plate lamp and connect the electrical consumers.
– Mount the electrical compartment.
3 SETUP
M00698-10
– Insert the black and violet cables of the bulb included in the
separate enclosure into the socket and position it in the turn
signal indicator lamp3.
– Position the turn signal on each side and mount and tighten
nuts5.
– Refit the headlight mask with the headlight. ( p. 28)
– Mount the footrests with the springs and pins. Secure the pins
using the washers and cotter pins.
Footrest spring plier (58429083000)
M00695-01
9
3 SETUP
– Mount the license plate holder with the license plate lamp,
turn signals, and reflector.
– Connect the electrical components.
Info
The cable of the left turn signal is marked red.
The cable of the right turn signal is marked green.
M00699-01
– Charge the 12 V battery. ( p. 23)
– Install the 12 V battery. ( p. 27)
– Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
C00740-01
H02556-01
M00700-01
– Make sure that the reflectors are glued on to the left and right
fork leg.
Info
The reflectors must not be covered by trim parts.
– Apply the sticker included in the delivery (optional).
– Mount the mirror clamps on both sides.
– Mount and tighten the rear mirror on both sides.
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M00701-01
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