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KTM 540 manual

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Table of contents for the manual

  • Page 1

    ERSA TZTEILKA T ALOG SP ARE P AR TS MANUAL '98 F AHRGESTELL / CHASSIS ART . NR. 3.204.39 2.98 400 540 SXC[...]

  • Page 2

    [...]

  • Page 3

    INHAL TSVERZEICHNIS INDEX 34 36 37 38 50 52 52 52 X D 6 7 6 9 7 7 10 12 32 33 40 40 42 43 44 52 52 54 55 1 2 13 99 2 75 75 13 76 7 49 17 21 24 36 37 12 32 34 12 11 30 38 40 44 42 46 47 68 68 68 56 56 56 56 53 54 55 55 79 78 71 70 1 31 45 43 46 47 41 64 63 61 66 34 25 24 20 35 5 6 1 2 4 16 15 11 9 12 13 17 3 12 12 14 Brake Fluid DOT 5.1 80 1 3 10 11[...]

  • Page 4

    INHAL TSVERZEICHNIS INDEX 12 29 26 18 16 15 17 19 2 20 38 38 38 28 9 8 8 36 27 7 8 30 25 13 14 15 9 8 41 5 11 3 4 6 7 2 22 10 12 2 10 11 12 1 20 16 17 40 18 16 15 17 14 13 12 11 13 12 70 10 51 52 42 21 22 20 S IG M A SIGMA S P O R T SPORT 5 0 0 500 6 7 8 10 11 12 13 14 23 24 25 26 27 28 21 30 31 35 1 12 12 9 8 8 10 6 5 7 VORNE FRONT 15 LOCTITE 242 [...]

  • Page 5

    INHAL TSVERZEICHNIS INDEX TECHNISCHE DA TEN - FAHRGESTELL 400 / 400/540 SXC Rahmen Zentralrohrrahmen aus Chrom-Molybdän-Stahlrohren Gabel WP Extreme Federweg vorne/hinten 285/320 mm Hinterradfederung Zentralfederbein (WP) mit PRO-LEVER-Anlenkung zur nadelgelagerten Alu-Hinterradschwinge Bremse vorne Scheibenbremse mit gelochter Bremsscheibe, Brems[...]

  • Page 6

    TELEGABEL WHITE POWER FRONT FORK WP 400/540 ‘98 34 36 37 38 50 52 52 52 X D 6 7 6 9 7 7 10 12 32 33 40 40 42 43 44 52 52 54 55 1 2 8 8 13 99 98-583.01.4 4 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.01.401.400 GABELBEIN LI. WP“0918S744“ ‘98 FORK LEG L/S WP „0918S744“ ‘98 1 2 583.01.402.400 GABELBEIN RE. WP“0918S744“ ‘98[...]

  • Page 7

    GABELBEINE WHITE POWER FORK LEGS WP 400/540 ‘98 ZUGSTUFE RECHTS REBOUND DAMPING RIGHT DRUCKSTUFE LINKS COMPRESS DAMPING LEFT 5 LITRE 5 L I T R E 5 zu to 5 zu to 2 3 6 11 10 22 5 zu to 23 24 23 24 30 32 5 zu to 35 5 8 16 36 5 zu to 42 42 40 43 42 42 38 43 1 3 5 zu to 6 5 zu to 22 5 zu to 30 5 zu to 32 35 5 8 16 36 5 zu to 70 34 34 98-546.01.1 5 FI[...]

  • Page 8

    LENKER, ARMA TUREN HANDLEBAR, CONTROLS 400/540 ‘98 90 94 40 48 42 43 46 49 45 45 44 41 47 3 1 CHOKE BET Ä TIGUNG SIEHE VERGASER! CHOKE SYSTEM SEE CARBURA TOR! 17 10 11 12 14 14 A C E R B IS A C E R B IS 28 820 98-583.02.2 6 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.02.001.300 ALU-LENKER SX,SC,ADVENTURE’97 ALU-HANDLEBAR SX,SC,ADVENT [...]

  • Page 9

    HANDBREMSZYLINDER HAND BRAKE CYLINDER 400/540 ‘98 21 10 9 12 11 15 20 23 25 1 16 BREMBO Brake Fluid DOT 5.1 80 97-546.13.6 7 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 502.13.001.044 HANDBREMSZYLINDER BREMBO’94 HANDBRAKE CYLINDER BREMBO ‘ 94 1 D=11MM D=11MM 9 502.13.012.000 DECKEL KPL. COVER CPL. 1 10 502.13.050.000 REP ARA TUR-SA TZ KO[...]

  • Page 10

    RAHMEN, AUSLEGER FRAME, SUB FRAME 400/540 ‘98 2 5 10 75 75 13 76 7 49 17 21 20 23 25 18 24 24 36 37 12 32 34 12 11 30 38 40 44 42 46 47 68 68 68 56 56 56 56 53 54 55 55 79 78 71 70 1 31 45 43 46 47 41 64 63 61 98-583.03.1 8 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.03.001.800 RAHMEN 400/540 SXC ‘98 FRAME 400/540 SXC ‘ 98 1 MIT LAGE[...]

  • Page 11

    RAHMEN, AUSLEGER FRAME, SUB FRAME 400/540 ‘98 2 5 10 75 75 13 76 7 49 17 21 20 23 25 18 24 24 36 37 12 32 34 12 11 30 38 40 44 42 46 47 68 68 68 56 56 56 56 53 54 55 55 79 78 71 70 1 31 45 43 46 47 41 64 63 61 98-583.03.1 9 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 56 0625 006087 RILLENKUGELLAGER 608 2RS C3 GROOVED BALL BEAR. 608 2RS C3 4 61[...]

  • Page 12

    SEITENSTÄNDER SIDE ST AND 400/540 ‘98 1 2 3 4 5 6 8 9 7 98-583.03.2 10 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.03.023.200 SEITENSTÄNDER KPL. L=381MM ‘97 SIDE ST AND CPL. L=381MM ‘ 97 1 2 583.03.026.250 SEITENSTÄNDERKONSOLE ‘97 SIDE ST AND BRACKET ‘ 97 1 3 0991 080353 SENKSCHRAUBE DIN7991-M 8X35 FLA T HEAD SCREW DIN7991-M 8[...]

  • Page 13

    SCHWINGARM,KETTENSCHUTZ SWINGARM, CHAIN GUARD 400/540 ‘98 40..44 71 72 73 30 72 71 39 38 44 43 40 41 41 42 43 44 12 14 15 90 91 86 85 60 64 67 68 89 90 39 16 73 98-583.04.5 11 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 12 546.03.014.000 SCHWINGARMBOLZEN 15X250 SWINGARM BOL T 15X250 1 14 502.30.211.000 BREMSSCHLAUCHFÜHRUNG ‘89 BRAKE HOSE GU[...]

  • Page 14

    PRO LEVER ANLENKUNG PRO LEVER SYSTEM 400/540 ‘98 32 6 5 6 5 8 9 8 5 5 5 6 6 4 3 2 2 3 10 11 30 20 51 50 50 51 52 54 54 32 20 1 30 15 15 15 15 97-583.04.9 12 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.03.080.144 WINKELHEBEL KPL. ‘94 ROCKER ARM CPL. ‘ 94 1 2 546.03.097.000 NADELHÜLSE HK 2016 NEEDLE BUSH HK 2016 4 3 546.03.081.000 LAG[...]

  • Page 15

    FUSSBREMSBETÄTIGUNG REAR BRAKE CONTROL 400/540 ‘98 60 63 66 67 66 50 50 34 26 25 24 20 33 30 32 35 5 6 1 2 4 16 15 11 9 12 13 17 3 12 12 14 51 Brake Fluid DOT 5.1 80 98-583.13.7 13 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 0991 080353 SENKSCHRAUBE DIN7991-M 8X35 FLA T HEAD SCREW DIN7991-M 8X35 1 2 583.03.061.000 F ASONSCHEIBE ALU 8 X 24 M[...]

  • Page 16

    FEDERBEIN WHITE POWER SHOCK ABSORBER WP 400/540 ‘98 1 3 10 11 12 14 15 16 16 17 20 25 7 8 FEDER / SPRING / RESSORT Weich / soft / douce Hart / hard / dure 54-260 57-260 60-260 63-260 66-260 70-260 95-583.04.2 14 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 583.04.010.800 MONOSHOCK WP „0118Q782“ ‘96 MONOSHOCK WP „ 0118Q782 “ ‘ 96 1[...]

  • Page 17

    KRÜMMER, VORSCHALLDÄMPFER PIPES, PRE SILENCER 400/540 ‘98 20 21 24 25 4 28 3 22 23 26 23 30 31 36 40 41 42 34 40 41 42 32 98-583.05.3 15 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 3 583.05.053.001 KERAMIKSCHNUR 1 METER CERAMIC LINE 1 METER 1 4 543.09.036.000 ZUGFEDER L=38MM RETURN SPRING L=38 MM 4 20 583.05.065.044 HAL TERUNG-VORSCHALLDÄM.[...]

  • Page 18

    ENDDÄMPFER SILENCER 400/540 ‘98 69 69 68 48 66 67 65 64 48 60 60 61 62 62 63 81 16 15 82 83 84 85 C O M P E T IT IO N S X C 98-583.05.4 16 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 15 0011 480752 BLINDNIETE 4,8X 7,5 NIRO DUMMY RIVET 4,8X 7,5 NIRO 10 16 503.05.016.000 ZUGFEDER L=55MM ÖSEN BEWEGLICH TENSION SPRING L=55MM 2 48 546.03.048.100 [...]

  • Page 19

    LUFTFIL TERKASTEN AIR FIL TER BOX 400/540 ‘98 12 29 26 18 16 15 17 19 2 10 20 40 39 38 38 38 28 9 8 8 36 27 7 8 98-583.06.1 17 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 2 583.06.001.200 FIL TERKASTEN KPL. OHNE SLS ‘94 FIL TER BOX CPL. WITHOUT SLS ’ 94 1 7 583.06.002.100 FIL TERKASTENDECK.MIT VLIES ‘97 FIL TER BOX COVER WITH VLIES ’ 9[...]

  • Page 20

    T ANK,SITZBANK,VERKLEIDUNG T ANK,SEA T ,COVER 400/540 ‘98 13 28 22 21 81 48 44 43 14 11 41 40 20 19 18 50 10 17 16 21 23 24 7 8 9 45 21 68 52 42 52 67 46 6 4 98-583.07.2 18 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 4 511.07.004.000 BENZINHAHN KPL.MIKUNI CK-69’96 FUEL COCK CPL.MIKUNI CK-69 ‘ 96 1 EIN ANSCHLUSS ONE CONNECTION 6 583.07.106.[...]

  • Page 21

    MASKE, KOTFLÜGEL MASK, FENDERS 400/540 ‘98 9 21 64 54 22 8 7 5 20 10 2 3 53 62 6 65 52 55 56 18 98-583.08.4 19 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 2 502.11.401.100/04 SCHEINW .MASKE UFO ORANGE ‘98 HEADLIGHT MASK UFO ORANGE ‘ 98 1 3 503.08.002.000 MASKENGUMMI UFO D=50MM ‘97 MASK RUBBER UFO D=50MM ‘ 97 2 5 0015 050123 SK.BUNDSCH[...]

  • Page 22

    DEKOR DECAL 400/540 ‘98 1 23 5 98-583.08.5 20 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 576.08.099.000 DEKORSA TZ 400/540 SXC ‘98 DECAL SET 400/540 SXC ‘ 98 1 2 576.08.091.100 HUBRAUMDEKOR „400 SXC“ ‘98 DISPLACEMENT DECAL “ 400SXC “ ‘ 98 1 3 576.08.091.200 HUBRAUMDEKOR „540 SXC“ ‘98 DISPLACEMENT DECAL “ 540SXC “ ?[...]

  • Page 23

    VORDERRAD FRONT WHEEL 400/540 ‘98 30 25 13 14 15 9 8 41 5 11 3 4 6 7 2 22 10 12 32 2 10 11 12 1 20 21 16 17 40 98-583.09.3 21 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 580.09.001.144/90 VORDERRAD 1,6X21“ DID ‘93 FRONT WHEEL 1,6X21 “ DID ‘ 93 1 2 546.09.010.044/90 VORDERRADNABE KPL.SILBER GS’93 FRONT HUB CPL. SIL VER GS ’ 93 1 3[...]

  • Page 24

    BREMSZANGE VORNE BRAKE CALIPER FRONT 400/540 ‘98 21 30 31 35 1 12 12 9 8 8 10 6 5 7 VORNE FRONT 15 LOCTITE 242 60 97-546.13.2 22 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 546.13.201.044 BREMSZANGE VORNE KPL.2 KOLBEN FRO.BRAKE CALIPER CPL. 2PISTON 1 5 546.13.205.000 REP ARA TURSA TZ 28MM REPAIR KIT 28MM 1 6 546.13.206.000 REP ARA TUR SA TZ [...]

  • Page 25

    HINTERRAD REAR WHEEL 400/540 ‘98 30 31 32 33 7 6 5 4 10 8 8 9 3 4 6 7 2 23 24 13 11 12 2 8 9 10 1 44 43 42 39 40 41 38 21 22 20 43 42 34 98-583.10.2 23 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 503.10.001.044 HINTERRAD KPL. 2.15X18“ DID’98 REAR WHEEL CPL.2.15X18 “ DID ’ 98 1 2 546.10.010.044/90 HINTERRADNABE KPL. SILBER REAR WHEEL [...]

  • Page 26

    BREMSZANGE HINTEN BRAKE CALIPER REAR 400/540 ‘98 7 3 4 2 5 6 10 11 12 13 1 97-583.13.1 24 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 502.13.301.644 BREMSZANGE KPL. HINTEN LINKS BRAKE CALIPER CPL. REAR L/S 1 2 546.13.318.200 REP ARA TUR SA TZ DICHTRINGE 34MM REPAIR KIT SEALING RINGS 34MM 1 3 546.13.310.200 BOLZENSA TZ BOL T SET 1 4 546.13.30[...]

  • Page 27

    SCHEINWERFER, RÜCKLICHT HEAD LIGHT , REAR LIGHT 400/540 ‘98 18 16 15 17 14 13 12 11 13 12 70 10 51 52 42 98-583.14.3 25 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 10 502.11.610.000 SCHEINWERFER KPL. ELCOM ‘93 HEADLIGHT CPL. ELCOM ‘ 93 1 11 502.11.631.000 STELLSCHRAUBE KPL. M4X40 ADJUSTING SCREW CPL. M4X40 1 12 502.11.410.050 SCHEINWERFER[...]

  • Page 28

    T ACHOANLAGE SPEEDOMETER 400/540 ‘98 21 22 20 S IG M A SIGMA S P O R T SPORT 5 00 500 6 7 8 10 11 12 13 14 23 24 25 26 27 28 98-583.14.5 26 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 6 583.14.069.000 T ACHOMET .SIGMA SPORT 500 ELEK. SPEEDOMET .SIGMA SPORT 500 ELEC 1 7 583.14.069.151 GEBERKABEL FÜR SIGMA 500 ‘98 CABLE FOR SIGMA 500 ‘ 98 1[...]

  • Page 29

    KABELSTRANG WIRING HARNESS 400/540 ‘98 11 12 5 51 2 4 17 18 20 35 5 10 80 81 29 30 31 32 33 7 8 21 13 13 36 37 19 98-583.11.3 27 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 2 583.11.175.500 HAUPTKABELSTRANG VORNE SXC ‘98 MAIN WIRING HARNESS FRONT SXC 1 4 583.11.176.100 RÜCKLICHTKABELSTR. ACERBIS ‘95 T AIL LIGHT WIRING ACERBIS ‘ 95 1 5 4[...]

  • Page 30

    ZUBEHÖR ACCESSORIES 400/540 ‘98 27 25 26 28 15 30 30 42 40 41 40 042 59 34 20 22 24 23 5 12 98-583.12.2 28 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 5 543.10.086.000 STOVERFLANSCHMUTTER M8 SELF LOCKING NUT M8 2 12 0934 080003 SK.MUTTER DIN0934-M 8 HEXAGON NUT DIN0934-M 8 1 15 584.02.001.050 AUFNAHMEKIT LENKER DUKE,ADV’97 SUPPOR TKIT F .HA[...]

  • Page 31

    [...]

  • Page 32

    TECHNISCHE DA TEN - F AHRGESTELL 400 / 540 SXC ‘98 400 /540 SXC Rahmen Zentralrohrrahmen aus Chrom-Molybdän-Stahlrohren Gabel WP Extreme Federweg vorne/hinten 285/320 mm Hinterradfederung Zentralfederbein (WP) mit PRO-LEVER-Anlenkung zur nadelgelagerten Alu-Hinterradschwinge Bremse vorne Scheibenbremse mit gelochter Bremsscheibe, Bremssattel sch[...]

  • Page 33

    TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC ‘98 400 / 540 SXC Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 285/320 mm (11,2/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated[...]

  • Page 34

    Motorölstand kontrollieren  Motoröl wechseln (SX, SXC, SC)   Motoröl wechseln (EGS)   Ölsieb und Magneten der Ablaßschrauben bei Motorölwechsel reinigen  Ölfiltereinsatz wechseln   Mikrofilter wechseln (SX, SXC, SC)  Feinfilter (Schraubfilter) am Rahmenbrustrohr wechseln   Ölleitungen auf Besc[...]

  • Page 35

    Check engine oil level  Change engine oil (SX, SXC, SC)   Change engine oil (EGS)   Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil  Change oil filter unit   Change microfilter (SX, SXC, SC)  Change fine screen filter (screwed filter) at the frame tube   Check oil l[...]

  • Page 36

    Gedruckt auf chlorfrei gebleichtem, umweltfreundlichen Papier. - aumayer-druck-mattighofen KTM-SPORTMOTORCYCLE AG A-5230 Mattighofen • Postfach 91 •Austria Internet: http://www .ktm.co.at FN 102019 d - Landesgericht Ried im Innkreis[...]