Checking Of Brake Fluid Level - Front Brake; Refilling The Front Brake Fluid Reservoir - KTM 625 SXC Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
30
2
A
B
1
3
4
5 mm
BRAKE FLUID:
We recommend that you use Motorex DOT 5.1 brake fluid when you refill or
change the brake fluid. DOT 5. 1 brake fluid has a wet boiling point of 180°C
(25°C higher than DOT 4) and is safer for high performance applications. Brake
fluid DOT 5.1 is a polyethylene glycol based fluid, amber-colored and can be
mixed with DOT 4 brake fluid.
Never use DOT 5 braking fluid. It is based on silicone oil and has a purple
color. Gaskets and brake hoses are not compatible with it.
Have the brake fluid changed at least once annually. If you wash your motor-
cycle often, the brake fluid should be changed even more frequently. Brake
fluid tends to absorb water. Therefore, vapor pockets may form in "old" brake
fluids even at low temperatures, causing the brake system to fail.
BRAKE DISCS:
Wear reduces the thickness of the brake disc in the area of contact [1] with
the brake pads. At its thinnest spot [A], the brake disc must not be more than
0.4mm thinner than its nominal dimension [B]. The nominal dimension can
be gaged in a location beyond the area of contact with the brake pads. Check
wear in several spots.
– Brake discs suffering from wear greater than 0.4 mm constitute a safety
hazard. Have the brake disc replaced immediately as soon as it reaches
its wear limit.
– As a matter of principle, have any repair of the brake system carried out
by a licensed KTM mechanic.

Checking of brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the han-
dlebar and the reservoir is provided with an inspection glass. With the reser-
voir in a horizontal position, the brake fluid level should not drop below the
middle of the glass. The reservoir should be kept completely full at all times
for best performance.
If the brake fluid level drops below the minimum either the brake system has
a leak or the brake pads are completely worn. In this case, consult an author-
ized KTM dealer immediately.

Refilling the front brake fluid reservoir *

When the brake fluid falls to the middle of the inspection glass, new brake
fluid has to be added.
Loosen screws [2] and remove lid [3] and membrane [4].
Place hand brake cylinder in a horizontal position and fill the brake fluid reser-
voir to 5 mm (0,2 in) below the rim with clean brake fluid DOT 5.1 (Motorex
Brake Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off
spilled or overflowing brake fluid with water.
– Never use DOT5 brake fluid! It is based on silicone oil and of a purple
color. Seals and brake hoses must be especially adapted to it.
– Store brake fluid out of reach of children.
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If
you get brake fluid in your eyes, rinse with plenty of water and consult a
doctor.
– Don't let brake fluid get in contact with paint, it is an effective paint remover.
– Use only clean brake fluid taken from a tightly sealed container.
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