Changing The Basic Position Of The Foot Brake Lever; Checking The Rear Brake Fluid Level; Refilling Rear Brake Fluid; Checking The Rear Brake Pads - KTM Super Duke 990s Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
1
28
4
min.
1 mm
6 mm
2
3

Changing the basic position of the foot brake lever *

Loosen the counternut [1] and turn the push rod [2] until the foot brake lever
is in the right position. Tighten the counternut again. For the best possible
connection, the push rod should be screwed at least 6 turns (6 mm) into the
heim joint (see drawing).
If the push rod is not screwed in far enough, the connection can brake and
cause the rear brake to fail in extreme cases.

Checking the rear brake fluid level

The brake fluid reservoir for the rear brake is located on the rear right of the
vehicle and has a "MIN" and a "MAX" mark. The brake fluid level may not fall
below the "MIN" mark when the vehicle is parked in an upright position.
– IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN.
IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.
– HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP
EVERY 2 YEARS.

Refilling rear brake fluid *

It is not necessary to refill brake fluid under normal conditions (see General
information on KTM disk brakes).
However, brake fluid must be refilled as soon as the brake fluid level reaches
the MIN mark.
Remove the cover [3] and rubber boot [4]. Add DOT 5.1 (Motorex Brake Fluid
DOT 5.1). Press the rubber boot together and remount the cover. Wash off
any overflowing or spilled brake fluid with water. Actuate the rear brake until
you feel the pressure point.
– ACTUATE THE REAR BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE.
– 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.

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).
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 AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL
RUB AGAINST THE BRAKE DISC, IMPARING THE BRAKING EFFECT AND DESTROY-
ING THE BRAKE DISC.
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