Replacing The Front Brake Pads; Changing The Basic Position Of The Foot Brake Pedal; Checking The Rear Brake Fluid Level; Refilling The Rear Brake Fluid Reservoir - KTM 250 SX 2003 Owner's Handbook Manual

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Replacing the front brake pads *

1
Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips
the brake caliper. Clean the brake caliper and the brake caliper support with
compressed air. Check the sleeves of the guide bolts for damage, and grease
guide bolts if necessary.
Mount the right brake pad and fix it with the bolt. Mount the left brake pad
and insert the bolt until it stops. Mount the clips.
When mounting the brake pads, be sure to check for correct fit of the
sliding metal-sheet
2
1
– I
– A
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3
4

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop
screw
means of the piston rod
Measured on the outside, the foot brake pedal must have 3-5 mm
(0.12–0.20 in) of free play before the piston rod can move the piston in the
brake cylinder (to be recognised from the resistance on the foot brake pedal).
I
F THIS FREE PLAY IS NOT PRESENT
WHEN DRIVING
AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES
3-5mm

Checking the rear brake fluid level

The reservoir for the rear disk brake is located on the right side of the bike
on the rear brake cylinder. The brake fluid level may not drop below the
mark
I
F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN
RIZED
A

Refilling the rear brake fluid reservoir *

Top up the brake fluid as soon as the brake fluid level reaches the mark
To top up, remove screw
Brake 5.1) up to the mark
screw. Spilled brake fluid must be rinsed off with water.
– N
B
– S
– B
– D
– U
1
and pull out bolt
3
in the caliper support and of the leaf spring
WARNING
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS
O ,
THERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED
,
FTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY
AFTER WORKING ON THE BRAKING SYSTEM
,
OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE
AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED
5
. The free play at the foot brake pedal must then be adjusted by
6
.
CAUTION
!
,
THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM
,
CAUSING THE REAR WHEEL TO BRAKE
A
when the bike is parked in a vertical position.
WARNING
KTM .
DEALER IMMEDIATELY
7 . Fill DOT5.1 brake fluid (e.g. Shell Advance
B
on the inside of the reservoir and remount the
WARNING
DOT5 ! I
EVER USE BRAKE FLUID
. S
COLOR EALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT
TORE BRAKE FLUID OUT OF REACH OF CHILDREN
RAKE FLUID CAN CAUSE SKIN IRRITATION
YOU GET BRAKE FLUID IN YOUR EYES
.
DOCTOR
! CAUTION
'
ON T LET BRAKE FLUID GET IN CONTACT WITH PAINT
.
VER
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER
2
. Remove brake pads from
.
.
,
ALWAYS ACTUATE THE HAND BRAKE LEVER
.
!
.T
HE BRAKING SYSTEM OVERHEATS
.
. I ,
N THIS CASE CONSULT AN AUTHO
T IS BASED ON SILICONE OIL AND OF A PURPLE
.
.
. A
VOID CONTACT WITH SKIN AND EYES
,
RINSE WITH PLENTY OF WATER AND CONSULT A
!
,
IT IS AN EFFECTIVE PAINT REMO
4
.
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