KTM SX-E 5 Manual

SETUP INSTRUCTIONS 2021

SX‑E 5

Art. no. 3214363en

INTRODUCTION

*3214363en*

3214363en

02/2021

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.

All specifications contained herein 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 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 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)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

SX‑E 5 (F3001U6)

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).

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.

1.2 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.

SETUP 2

2.1 Transport mode

H02712-01

This vehicle was blocked for transport in the software.

To operate the vehicle, the vehicle electronics must be enabled.

This process is conducted during initial setup in KTM Dealer.net.

Enabling ensures that the initial setup in KTM Dealer.net is docu-

mented.

Enabling can be performed either temporarily, e.g. for a test ride,

or permanently for vehicle handover.

Info

Make sure that the vehicle is permanently enabled before

handing it over to the customer.

2.2 Diagnostics connector

H03809-01

Diagnostics connector 1is located under the seat.

2.3 Unpacking and setting up the vehicle

M01926-01

–Open the box.

Guideline

To avoid damaging the vehicle while setting it up, do

not remove the protective film on each component until

installing the component, and leave it on the vehicle until

work has been completed.

–Remove the cable ties on the handlebar clamp.

–Remove wooden cover.

–Remove the separate enclosure and unpack it. Check the sepa-

rate enclosure for completeness.

Info

The procedure for missing components is described in

the Customer Service Manual.

401942-01

–Raise the motorcycle with a lift stand. ( p. 9)

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the Customer Service Manual.

2 SETUP

M01755-10

–Remove the start number plate. ( p. 6)

–Remove screws 1and handlebar clamps.

–Remove the protective film from the handlebar.

M01756-10

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the 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 with handlebar clamps.

Guideline

Make sure the cables and wiring are positioned correctly.

–Mount and tighten screws 1.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Make sure the installed gaps are even.

–Check the handlebar position.

» If the handlebar position is not adjusted as required by the

customer:

–Adjust the handlebar position. ( p. 6)

–Check that the controls on the handlebar are correctly posi-

tioned and firmly seated.

M01818-10

–Secure the cables of the magnetic switch and the throttle grip

to the handlebars with two cable ties each.

–Secure the handlebar cushion with two cable ties.

–Install the start number plate. ( p. 7)

SETUP 2

800042-10

–Mount the footrests with the springs and pins. Secure the pins

using the washers and cotter pins.

Footrest spring plier (58429083000)

–Install the motor guard. ( p. 10)

–Remove the remaining film, padding, the corrugated card-

board, and the other packaging material.

–Attach the stickers included in the scope of supply (optional).

–Carry out the procedure for unlocking the battery management

system. ( p. 15)

–Charge the Powerpack LV. ( p. 17)

–Prepare the vehicle according to the specifications in

KTM Dealer.net for handover to the customer.

Info

Transport mode must be deactivated to be able to start

the motorcycle.

H03605-01

–Check the factory-set frame height.

» If the frame height is unsuitable for the rider:

–Adjust the seat height on the shock absorber.

( p. 10)

–Adjust the seat height on the fork. ( p. 11)

–Adjust the seat height on the frame. ( p. 12)

3 WORK

3.1 Removing the start number plate

M01681-10

–Remove screw 1.

–Unhook the start number plate from the brake line and remove

it.

3.2 Adjusting the handlebar position

Warning

Danger of accidents A repaired handlebar poses a safety risk.

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged or bent.

M01659-11

–Remove screws 1. Take off the handlebar clamps. Remove

the handlebar and lay it to one side.

Info

Cover the components to protect them against damage.

Do not kink the cables and lines.

–Remove screws 2. Take off handlebar supports.

–Place handlebar supports in required position. Mount and

tighten screws 2.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Mount the left and right handlebar supports in the same

position.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount screws 1and tighten

evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Info

Make sure the installed gaps are even.

WORK 3

3.3 Installing the start number plate

M01682-10

–Attach the start number plate to the brake line.

–Position the start number plate.

Holding lugs 1engage in the fender.

M01683-10

–Mount and tighten screw 2.

Guideline

Screw, start number

plate

M6 4 Nm (3 lbf ft)

3.4 Installing front fender

M01671-10

–Position the fender with drill holes 1in the holding lugs on

the start number plate.

H01428-11

–Position front fender. Mount and tighten screws 2.

Guideline

Screw, fender M6 6 Nm (4.4 lbf ft)

3 WORK

3.5 Removing the front wheel

Preparatory work

–Raise the motorcycle with a lift stand. ( p. 9)

M01697-10

Main work

–Remove screw 1.

–Loosen screws 2.

M01698-10

Warning

Danger of accidents Damaged brake discs reduce the

braking effect.

–Always lay the wheel down in such a way that the

brake disc is not damaged.

–Hold the front wheel and remove the wheel spindle. Take the

front wheel out of the fork.

Info

Do not actuate the hand brake lever when the front

wheel is removed.

H00934-10

–Remove spacers 3.

3.6 Installing the front wheel

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

–Always keep the brake discs free of oil and grease.

–Clean the brake discs with brake cleaner when necessary.

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