Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Engine Code:
Specific to 540 SXS model (typically internal KTM designations)
Target Audience:
KTM 540 SXS owners, independent repair shops, DIY enthusiasts
Content Quality:
Original, Complete, Intact, Professional Quality, Highly Detailed
User Benefits:
Save money on repairs, perform maintenance confidently, quick access to critical information
Document Completeness:
Complete and intact, no missing or corrupt parts/pages.
Advantage Over Alternatives:
Instant digital access, printable sections, potentially factory-sourced information not found elsewhere
All Models Trims Engines:
Yes (covers all models, engines, trim, and transmission types for the specified years)
Specific Components:
Engine, Fuel System, Cooling System, Electrical System, Alternator, Regulator, Fuel Filter
Estimated Page Count:
Hundreds of pages (as stated in product description)
Type:
Workshop Repair Service Manual
Engine:
Engine Identification, Engine Body, Fuel System, Cooling System, Alternator, Regulator
Electrical:
Electrical System, Wiring Diagrams
Chassis:
General Precautions, Special Tools, Servicing Specifications, Tightening Torques
Fuel System:
Fuel System, Fuel Filter
Frame:
Frame specifications and potential repair guidance (likely limited, focus on mechanical systems).
Suspension:
Suspension system adjustment and maintenance procedures (e.g., fork oil, seal replacement, shock service).
Maintenance:
Maintenance Check List, Check and Maintenance
Repair:
Disassembling and Servicing, Troubleshooting, Detailed substeps expand on repair procedure information
Diagnostics:
Troubleshooting, Diagnostic information, Electrical service procedures
Assembly:
Yes (detailed in Disassembling and Servicing sections)
Cleaning:
Yes (cleaning and re-installing procedures mentioned)
Troubleshooting Electrical:
Combined troubleshooting and electrical service with detailed wiring diagrams
Reinstallation:
Yes (procedures for cleaning and reinstalling components)
Depth:
Comprehensive (used by professional technicians, covers detailed repair and maintenance)
Precision:
Precise specifications, tightening torques, and diagrams for accurate repairs.
Diagnostic Codes:
While not explicitly stated, comprehensive troubleshooting often includes interpreting diagnostic indicators.
Special Tools:
List of required special tools for specific procedures.
Engine Type:
Likely single-cylinder, four-stroke (typical for KTM SXS models of that era, specific details require manual inspection)
Displacement:
540cc (as per model name)
Estimated Horsepower:
Likely in the range of 55-65 HP, exact figures in manual.
Estimated Torque:
Specific torque figures detailed in manual.
Carburetion:
Likely a high-performance carburetor (e.g., Keihin PWK series, specific model detailed in manual)
Bore Stroke:
Specific bore and stroke dimensions are detailed within the manual.
Compression Ratio:
Specific compression ratio detailed in manual for optimal performance.
Oil Change Interval:
Specific intervals provided in manual, typically based on operating hours for racing applications.
Air Filter Cleaning:
Frequent cleaning recommended, detailed procedure in manual.
Engine Oil Type:
Specific viscosity and API rating for KTM 4-stroke motocross engines (e.g., Motorex Power Synt 4T 10W/50, full specs in manual).
Coolant Type:
Specific mixture of antifreeze and distilled water, often with corrosion inhibitors (details in manual).
Brake Fluid Type:
DOT 4 recommended for hydraulic brake systems.
Clutch Fluid Type:
DOT 4 recommended for hydraulic clutch systems.
Gearbox Oil Type:
Specific gearbox oil and quantity detailed in manual.
Common Wear Items:
Piston rings, valve seals, clutch plates, chain and sprockets (typical for high-performance off-road use).
Carburetor Tuning:
Requires periodic cleaning and adjustment for optimal performance in varying conditions.
Typical Maintenance Items:
Spark plug replacement, chain lubrication and adjustment, tire pressure checks, bearing lubrication.
Heritage:
KTM is renowned for its off-road racing heritage, particularly in motocross and enduro.
Sx Series:
The SXS designation typically indicates a factory-prepped or special edition version of KTM's motocross (SX) line, often with performance enhancements.
Sx Vs Sxs:
SXS models are often a step above the standard SX in terms of factory upgrades and tuning for racing.
Manufacturing Location:
Austria (primary KTM manufacturing)
