Refilling The Front Brake Fluid Reservoir; Checking The Front Brake Pads; Replacing Front Brake Pads - KTM DUKE 640 e Owner's Handbook Manual

1
3
5 mm
min.
1 mm
4
7

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.
2
Loosen screws
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm below the rim with brake fluid (DOT 5.1). Replace mem-
brane and lid, tighten screws. Rinse off spilled or overflowing brake fluid
with water.
R
EFER TO WARNING IN THE CHAPTER ON

Checking the front brake pads

The brake pads can be inspected from behind. Always inspect the brake
pad linings before taking off on your motorcycle. They should not be thinner
than 1 mm which is the case when the notch
A
T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN
,
MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE
PUT OFF HAVING YOUR BRAKE PADS CHANGED
I
F THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTI
RELY WORN AWAY
,
BRAKE DISC SIGNIFICANTLY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC

Replacing front brake pads*

5
Remove clip
brake caliper. Remove retainer spring
the brake pistons far enough back to allow the new brake pads to be put in
place. Before installing the new brake pads, however, the brake caliper
should be cleaned thoroughly using compressed air.
6
Insert new brake pads into the brake caliper, replace retainer spring (arrow
pointing upward), and reinsert cotter bolt. Hammer the bolt into the caliper
as far as it will go and replace cotter pin.
– I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE
OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED
– A
FTER ASSEMBLY
– A
FTER WORKING ON THE BRAKE SYSTEM
SO THAT THE BRAKE PADS LIE AGAINST THE BRAKE DISC AND THE PRESSURE POINT IS
ESTABLISHED
– D
O NOT OPERATE THE HAND BRAKE UNLESS THE BRAKE PADS ARE PROPERLY IN PLACE
1 and remove lid 2 and membrane
WARNING
"
GENERAL INFORMATIONS ABOUT
WARNING
.
CAUTION
!
,
THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE
5
and using a mandrel knock the cotter bolt
7
. Using the old brake pads, push
WARNING
,
CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY
,
OPERATE THE HAND OR THE FOOT BRAKE
.
3 .
D B "
ISC RAKES
4
is no longer discernable.
. F
OR YOUR OWN SAFETY DON
!
6
out of the
.
.
.
21
1
'
T
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.
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