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.
© 2021 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)
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
2
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
3
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
4
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
5
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
6
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
7
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
8
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.

WORK 3
9
H01198-10
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease the contact surfaces Aof the spacers.
Long-life grease ( p. 22)
–Insert the spacers.
M01698-11
–Clean and grease the wheel spindle.
Long-life grease ( p. 22)
–Position the front wheel.
The brake linings are correctly positioned.
–Insert the wheel spindle.
M01697-10
–Mount and tighten screw 1.
Guideline
Screw, front
wheel spindle
M10 40 Nm (29.5 lbf ft)
Loctite®243™
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 10)
–Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–Tighten screws 2.
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
3.7 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78929955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.

3 WORK
10
3.8 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.
402581-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand 1into the plug-
in stand bracket on the left side of the vehicle.
Info
Remove the plug-in stand before riding.
3.9 Installing the motor guard
T04024-11
–Attach the motor guard on the frame at the rear and swing up
at the front.
–Mount and tighten screws 1and 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.10 Adjusting the seat height on the shock absorber
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris-
tic.
–Make sure your child rides slowly to start with after making adjustments in order that he or she can
assess the new handling characteristic.
Info
If the seat height is adjusted on the shock absorber, the seat height should also be adjusted on the fork.
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 9)
M01660-10
Main work
–Hold the rear wheel with the link fork and remove screw 1.
–Position the shock absorber according to the required seat
height.
Guideline
High seat position A
Low seat position B
–Mount and tighten screw 1.

WORK 3
11
Guideline
Screw, top
shock absorber
M10 45 Nm (33.2 lbf ft)
Loctite®243™
Finishing work
–Remove the motorcycle from the lift stand. ( p. 10)
3.11 Adjusting the seat height on the fork
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris-
tic.
–Make sure your child rides slowly to start with after making adjustments in order that he or she can
assess the new handling characteristic.
Info
The seat height can be infinitely adjusted by pushing the fork legs through.
If the seat height is adjusted on the fork, the seat height should also be adjusted on the shock absorber.
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 9)
–Remove the front wheel. ( p. 8)
M01811-10
Main work
–Loosen screw 1.
–Loosen screw 2.
–Position the fork leg according to the required seat height.
Guideline
Condition
Seat position as low as possible, fork fully inserted
Minimum distance A
between the fork and han-
dlebar
3 mm (0.12 in)
Condition
Seat position as high as possible, fork pulled out com-
pletely
Bottom edge of screw cap Bcloses flush with the
upper edge of the triple clamp
Position the fork leg only within the described range.
–Tighten screw 2.
Guideline
Screw, bottom triple
clamp
M8 15 Nm (11.1 lbf ft)
–Tighten screw 1.
Guideline
Screw, top triple
clamp
M8 20 Nm (14.8 lbf ft)
–Repeat the procedure on the other fork leg.

3 WORK
12
Guideline
Position both fork legs equally.
Finishing work
–Install the front wheel. ( p. 8)
3.12 Adjusting the seat height on the frame
Preparatory work
–Remove the seat. ( p. 14)
M01675-10
Main work
–Remove screw 1and the front fairing.
M01676-10
–Remove screws 2with bushings and splash protector 3.
–Remove screws 4with bushings and rear fairing 5.
M01677-10
–Remove screws 6and position subframe 7at the drill
holes at the desired seat height.
Guideline
Pay attention to the wiring harness.
High seat position Drill holes A
Low seat position Drill holes B
–Mount and tighten screws 6.
Guideline
Screw, sub-
frame
M8 30 Nm (22.1 lbf ft)
Loctite®243™

WORK 3
13
M01676-10
–Position rear fairing 5, mount screws 4with bushings, and
tighten.
Guideline
Rear fairing screw M6 8 Nm (5.9 lbf ft)
–Position splash protector 3, mount screws 2with bushings,
and tighten.
Guideline
Screw, splash protec-
tor
M6 8 Nm (5.9 lbf ft)
M01678-10
Condition
High seat position
–Make sure that thread adapter 8is mounted and tight-
ened.
Guideline
Threaded adapter
for front fairing
M6 8 Nm (5.9 lbf ft)
M01679-01
Condition
Low seat position
–Make sure that the thread adapter is removed.
Info
Retain the thread adapter for later assembly.
M01680-10
–Position the front fairing on holders C.
The holding lugs of the front fairing engage in the
recesses of the rear fairing on both sides.

3 WORK
14
M01675-10
–Mount and tighten screw 1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
Finishing work
–Mount the seat. ( p. 14)
3.13 Removing the seat
H00066-10
–Open quick release 1and raise the rear of the seat.
–Pull back the seat and remove it.
3.14 Mounting the seat
M01684-10
–Hook the seat onto holding lug 1, lower the seat at the rear,
and push it forward.
Holding lug 2hangs on the front fairing.
H00066-11
–Close quick release 3.

WORK 3
15
3.15 Unlocking procedure for the battery management system
M01769-51
–Connect the diagnostics tool and start it.
–Select the vehicle in the diagnostics tool.
–Ensure external power supply for VCI using 12-V battery.
–Connect battery charger to the 12-V battery.
–Execute "Battery management system" >"Functions" >"Activate/deactivate transport mode".
–Clear the fault memory using the KTM diagnostics tool.
–Read out the fault memory using the KTM diagnostics tool.
» When fault memory is empty:
work is complete.
3.16 Positioning 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 Powerpack.
–Only use the battery charger with a Powerpack.
–Only operate the battery charger using household sockets with a ground conductor.
–Do not use any additional adapters or extensions.
–Follow the applicable safety instructions of the power connection.

3 WORK
16
Warning
Risk of injury There is a risk of electric shock if the battery charger or the cables have been manipulated
or damaged.
The battery charger does not contain any parts which require maintenance.
–Do not modify the battery charger or the cables.
–Only use original cables.
–Never open the battery charger housing.
–Do not insert any objects into the battery charger housing from the outside.
–Do not use the battery charger if cables, plugs, or parts of the battery charger have been damaged or
are soiled.
Info
The battery charger contains sensitive electronics and must be handled with appropriate care.
The battery charger may be damaged or destroyed if it is dropped, knocked or otherwise subject to
mechanical overload.
When transporting the battery charger, ensure appropriate means of securing the cargo.
Damage caused due to improper handling or improper transport is excluded from the manufacturer war-
ranty.
The battery charger only meets IP66 when the original power cord is being used.
M01630-01
–Place the battery charger on a firm, level, and horizontal sur-
face.
Info
Despite IP66, the battery charger should only be used
in a dry environment, as moisture may penetrate into
the interior when connecting and disconnecting the
connections.
–Check the battery charger and mains cable for external dam-
age.
–Ensure the battery charger is adequately ventilated.
–Use the battery charger in the temperature range permitted.
Guideline
Ambient temperature −20 … 50 °C (−4 …
122 °F)
Temperature range of the
Powerpack LV
0 … 50 °C (32 … 122 °F)
Do not operate the battery charger directly in a warm envi-
ronment if it has previously been stored in a cold environ-
ment.
Info
The change in temperature can cause moisture to con-
dense on the battery charger.
–Ensure that the power plug for the battery charger always
remains easily accessible.

WORK 3
17
3.17 Charging the Powerpack LV
Caution
Danger of burns The metal housing of the battery charger becomes hot during operation.
–Only touch the battery charger by the carrying handle.
–After charging, allow the battery charger to cool before stowing it away.
Note
Material damage The power supply will be damaged in the event of an overload.
–Ensure that the power outlet can supply the steady current required and is protected by a suitable fuse.
Fuse protection at mains voltage 100 V minimum 15 A
Fuse protection at mains voltage 120 V minimum 13 A
Fuse protection at mains voltage 230 V minimum 10 A
Note
Environmental hazard A lithium-ion battery (Powerpack LV) contains components and elements that are
harmful to the environment.
–Never throw a Powerpack LV into the household trash.
–Dispose of the Powerpack LV properly and in compliance with the applicable regulations.
Info
Do not activate the vehicle while the battery charger is connected to the Powerpack LV.
If the vehicle is activated during the charging process, the vehicle switches to the malfunction state.
Info
If the temperature of the Powerpack LV exceeds the permissible value while it is being charged, the bat-
tery charger stops charging. The malfunction is displayed on the multifunctional element.
After the temperature of the Powerpack LV returns to the permissible range, charging is resumed automat-
ically.
Preparatory work
–Position the battery charger. ( p. 15)
–Press and hold the On/Off button until the multifunctional ele-
ment goes out.
–Remove the magnetic switch from the holder on the handle-
bar.
M01685-10
Main work
–Remove charging socket protection cap 1.

3 WORK
18
M01686-10
–Remove charging plug protection cap 2.
M01687-10
–Make sure that all plugs, bushings, and cables are dry.
Warning
Risk of injury The intrinsic safety of the Powerpack LV
can only be guaranteed if the original battery charger
is used.
The Powerpack LV may only be charged with the orig-
inal battery charger.
–Only use the original battery charger to charge the
Powerpack LV.
–Connect the battery charger to the Powerpack LV.
Guideline
Observe plug marking A.
Insert the plug straight so that the contacts are not bent.
M01728-02
–Connect the power plug for the battery charger to the mains
connection.
Charging starts automatically.
The multifunctional element indicates the charging level.
–Monitor the charging level of the Powerpack LV on the
multifunctional element.
Info
It is recommended not to leave the vehicle unattended
for long periods during charging.
When charging is complete, three beeps are emitted
and all segments of the charging level indicator light up
continuously.
–Press and hold the On/Off button until the multifunctional ele-
ment goes out.
M01728-01
–Make sure that all plugs, bushings, and cables are dry.
–Disconnect the battery charger power plug from the mains con-
nection.