KTM Freeride E-XC 2019 Setup Instructions Download

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SETUP INSTRUCTIONS

2019

Freeride E

‑

Art. no. 3213880en

Summary of Contents for Freeride E-XC 2019

Page 1: ...SETUP INSTRUCTIONS 2019 Freeride E XC Art no 3213880en ...

Page 2: ......

Page 3: ... 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 produc tion of a particular model without prior notice KTM accepts no liability for delivery options deviations from fig ures and descriptions misprints and other errors The models portrayed partly contain special equ...

Page 4: ...k 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 a...

Page 5: ...s 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 ...

Page 6: ...owed to operate the product described safely Therefore read this instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you o...

Page 7: ...ause 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 However should the vehicle catch fire inform the fire brigade responsible that an electric vehicle with a rechargeable li...

Page 8: ...king and setting up the vehicle E00851 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 and unpack the separate enclosure and components Check that the scope of supply is complete using the enclosed packing list Info The pr...

Page 9: ...ansport damage is described in the customer service manual F01849 10 Remove the spare key and KEYCODECARD keep in a safe place for the handover Loosen rubber strap 1 and tilt the headlight mask forwards E00971 10 Disconnect the plug in connector 2 of the headlight and the plug in connector 3 of the ignition lock Lay down the headlight mask carefully to the side and protect from damage F01234 01 Ma...

Page 10: ...he handlebar is bent or straightened the mate rial becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 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 handlebar clamps and scre...

Page 11: ...ute the cable without tension and secure with cable ties and cable holders 402390 01 Mount turn signal switch and route cable to the front F01848 01 Position the controls on the left half of the handlebar Route the cable without tension and secure with cable ties and cable holders ...

Page 12: ...3 SETUP 10 H01060 01 Mount the mirror clamps on both sides F01859 01 Mount and tighten the rear mirror on both sides E00962 01 Preassemble the hand guards on the left and right ...

Page 13: ...osition the front fender Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 6 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F01847 01 Release the axle clamp screws and remove the wheel spindle Install the front wheel p 21 ...

Page 14: ...lay 7 with lock washer 8 and screw 9 E00967 01 Position the turn signal on both sides on the license plate holder mount nuts with washers and tighten F01855 10 Position the license plate lamp on the license plate holder extension and mount and tighten screw bk F01856 10 Mount reflector bl on the license plate holder with the spring washer ...

Page 15: ...cator lamps W2 3W socket W2x4 6d Position the cable with socket and bulb in turn signal control lamp bm Install the headlight mask with the headlight p 33 Check the headlight setting p 33 F01851 10 Fold the seat up p 22 Remove 12 V battery bp Charge the 12 V battery p 27 F01861 10 Remove screws bq and hang the battery compartment to the side F01877 10 Remove screws br Remove screws bs Lower the li...

Page 16: ...ten screws bq Info The wiring harness runs under the battery compart ment Lock the seat p 22 F01878 10 Route the turn signal cable on the left side on the license plate holder and feed the turn signal cable through the hole Route the cable of the tail light on the right side on the license plate holder F01876 10 Position the license plate holder on the rear Info Ensure that the cable is routed cor...

Page 17: ...Connect the plug in connector of the left turn signal which is marked red Connect the plug in connector of the right turn signal which is marked green Position the license plate holder extension on the license plate bracket Info Make sure the cables and plug in connections are posi tioned correctly Mount and tighten screws bt M00695 01 Mount the footrests with the springs and pins Secure the pins ...

Page 18: ...d locked F01874 10 Position the wiring harnesses ferrite core and brake line on the motor Position clamp cl F01872 10 Mount and tighten screw ck Guideline Remaining screws for motor M6 10 Nm 7 4 lbf ft The clamp is fully closed but the cable is not pinched F01875 10 Mount the cable ties Carry out the unlocking procedure for the KTM PowerPack p 22 Charge the KTM PowerPack p 25 Set the combination i...

Page 19: ...ng KTM PowerParts fitting instruc tions Remove remaining protective film Attach the stickers included in the scope of supply optional Prepare the vehicle according to the specifications in the KTM Dealer net for handover to the customer ...

Page 20: ...hicle Lift stand 78129955100 Neither wheel is in contact with the ground Secure the motorcycle against falling over 4 2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Main work Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand...

Page 21: ...ge 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 19 Fold the seat up p 22 Remove the KTM PowerPack p 29 Option HV 2 technical personnel Ascertain that the KTM PowerPack is at zero potential p 36 Ascertain that the discharge plug is de energized p 37 F01672 10 Main work Check the battery d...

Page 22: ...ck installed p 37 Lock the seat p 22 4 6 Checking the battery discharge plug form ring Condition The KTM PowerPack has been removed The protection cap has been removed F01673 10 Check battery discharge plug form ring 1 on the electric motor If the battery discharge plug form ring is dirty Ascertain that the discharge plug is de energized p 37 Clean the form ring without using water or compressed a...

Page 23: ... grease the wheel spindle Long life grease p 41 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the front brake lever several times until the brake lin ings are in contact with the brake disc Remove the motorcycle from the lift stand p 18 Operate the fron...

Page 24: ...n of the arrow Lift the seat and fold it up 4 9 Locking the seat F01671 10 Fold down the seat and push it down The seat engages with an audible click Finally check that the seat is correctly locked 4 10 Unlocking procedure for KTM PowerPack Condition The KTM PowerPack has been removed ...

Page 25: ...attery charger in dry conditions 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 Only operate the battery charger using household sockets with an earth conductor Do...

Page 26: ...ide of the battery charger 20 cm 7 9 in Use the battery charger in the temperature range permitted Guideline Ambient temperature 15 50 C 5 122 F Ensure that the power plug for the battery charger always remains easily accessible 4 12 Checking residual current protection switch K00031 10 Warning Risk of injury There is a risk of electric shock with a faulty residual current protection switch Before...

Page 27: ...icle 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 Info When the left LED in the charging level indicator on the battery charger flashes the KTM PowerPack is ready for use However full capacity is not yet available To guarantee t...

Page 28: ...Connect the power plug for the battery charger to the mains connection Set the charging mode switch 2 to the Fast position or Nor mal position Info In charging mode Fast the KTM PowerPack is com pletely charged after approx 105 minutes The power consumption is higher than in charging mode Normal In charging mode Normal the KTM PowerPack is com pletely charged after approx 135 minutes C00769 10 Swi...

Page 29: ... or worn Change the seal Mount the charging socket protection cap Finishing work Lock the seat p 22 4 14 Charging 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 Keep sparks or open flames away from the 12 V battery Only charg...

Page 30: ...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 Deactivate the vehicle p 19 Fold the seat up p 22 Remove the 12 V battery p 31 A00134 10 Main work Connect the battery charger to the 12 V battery Adjust the battery charger EU battery charger XCharge professional ...

Page 31: ... PowerPack into the household trash Dispose of the KTM PowerPack properly and in compliance with the applicable regulations Preparatory work Deactivate the vehicle p 19 Fold the seat up p 22 402145 11 Main work Loosen screws 1 Note Material damage Components damaged or destroyed by water or dirt Mount the protection cap after you have removed the KTM PowerPack Place the KTM PowerPack on a clean an...

Page 32: ...ischarge socket without using water or compressed air if the battery discharge plug or the battery discharge socket is dirty After cleaning spray silicone spray onto the battery discharge plug form ring Preparatory work Option HV 2 technical personnel Perform an equipotential bonding check KTM PowerPack installed p 37 Main work Remove the protection cap p 20 Check the battery discharge plug form r...

Page 33: ...ries as household waste Dispose of 12 V batteries at a collection point for used batteries Preparatory work Deactivate the vehicle p 19 Fold the seat up p 22 F01684 10 Main work Detach rubber strap 1 Disconnect negative cable 2 from the 12 V battery Disconnect positive cable 3 from the 12 V battery Remove the 12 V battery 4 18 Installing the 12 V battery Warning Risk of injury Battery gases cause ...

Page 34: ... fender E00985 10 Main work Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 33 Install the KTM PowerPack p 30 Option HV 2 technical personnel Perform an equipotential bonding check KTM PowerPack inst...

Page 35: ...gs on the headlight mask engage in the fender Finishing work Install the KTM PowerPack p 30 Option HV 2 technical personnel Perform an equipotential bonding check KTM PowerPack installed p 37 Lock the seat p 22 Check the headlight setting p 33 4 21 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of...

Page 36: ...etting p 33 E00975 10 Main work Loosen screw 1 Adjust the headlight range by pivoting the headlight Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider instructions on how to apply the mark Checking the headlight setting Info A change in weight on the vehicle may require a correc tion of the headlight range Tighten screw 1 4 23 Setting the co...

Page 37: ...appears 4 24 Setting the kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds The Setup menu is displaye...

Page 38: ...conds can only be set to zero If no button is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 4 26 Ascertaining that the KTM PowerPack is at zero potential Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM Powe...

Page 39: ... 28 Performing an equipotential bonding check KTM PowerPack installed Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM PowerPack has been removed 309699 10 Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start software HV Safety Select Equipotential bonding check Follow th...

Page 40: ...battery discharge plug form ring Preparatory work Check the battery discharge plug form ring p 20 Ascertain that the discharge plug is de energized p 37 309692 10 Main work Remove the form ring 1 309693 10 Spray silicone spray onto the new form ring Mount the form ring Finishing work Install the KTM PowerPack p 30 Option HV 2 technical personnel Perform an equipotential bonding check KTM PowerPack...

Page 41: ...rew M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 10 Nm 7 4 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 18 Nm 13 3 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw ...

Page 42: ...3 Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Nut swingarm pivot M14x1 5 75 Nm 55 3 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft ...

Page 43: ...AUXILIARY SUBSTANCES 6 41 Long life grease Recommended supplier MOTOREX Bike Grease 2000 ...

Page 44: ... 3213880en 3213880en 01 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM ...

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KTM Freeride E-XC 2019, Setup Instructions

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