Changing The Basic Position Of The Handbrake Lever; Checking Of Brake Fluid Level - Front Brake; Refilling The Front Brake Fluid Reservoir; Checking The Front Brake Pads - KTM 660 SMC 2005 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
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Changing the basic position of the handbrake lever

The adjusting screw [1] allows you to change the basic position of the hand-
brake lever [2].
Press the handbrake lever's outer end forward, and, at the same time, turn
the adjusting screw.
2

Checking of brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the
handlebar 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 AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws [3] and remove lid [4] and membrane [5].
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 PUR-
PLE 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.
5 mm

Checking the front brake pads

The brake pads can be inspected from behind. Always inspect the brake pad
min.
linings before taking off on your motorcycle. They should not be thinner than
1 mm 1 mm which is the case when the notch [A] is no longer discernable.
AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER
THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN
SAFETY DON'T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY
OR ENTIRELY WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB
AGAINST THE BRAKE DISC, THEREBY IMPARING THE BRAKING EFFECT AND
A
DESTROYING THE BRAKE DISC.
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