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MAINTENANCE WORK ON CHASSIS AND ENGINE
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4
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Replacing the front brake pads *
Turn the upper bolt [1] approx. 45° in a clockwise direction with a wrench
until you see the stopper [2]. Remove the stopper on both bolts, pull out the
bolts and demount the retaining spring [3].
Carefully press against the brake pads with a screwdriver to move the brake
pistons into the basic position. Remove brake pads from the brake caliper and
clean the brake caliper thoroughly with compressed air.
Slide new brake pads in the brake caliper and mount a bolt [4] to help find
the right position. The bolt must fit through the [A] holes in the brake pads
(see illustration).
3
Remove the bolt, position the retaining spring (be careful not to move the
brake pads) and mount both bolts. Mount the stoppers and turn the upper
bolt approx. 45° in a counter-clockwise direction until the stopper is under
the retaining spring.
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
– HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST
ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER, RESPEC-
TIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE
DISK AND THE PRESSURE POINT IS ESTABLISHED.
Check the rear brake fluid level
The reservoir for the rear disc brake is located above the main brake
cylinder. The level of brake fluid may not fall below the „MIN" mark when
the vehicle has been left standing upright.
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 rear brake fluid reservoir *
When the brake fluid level has dropped to the MIN mark, you need to refill
the brake fluid reservoir.
For easier access to the brake fluid reservoir it is recommended to remove the
hexagon screw [5]. Then move the container outwards as indicated in the illus-
5
tration. Remove plug [6] with rubber boot [7] and add brake fluid DOT 5.1
(Motorex Brake Fluid DOT 5.1) up to the „MAX" mark. Replace rubber boot
and plug. Overflown or spilled brake liquid must be rinsed off with water. Mount
the screw and fix the brake fluid reservoir to the frame, always making sure
to prevent kinks in the connecting hose.
– 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.
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