Changing Basic Position Of The Brake Pedal; Checking The Rear Brake Fluid Level; Refilling The Rear Brake Fluid Reservoir; Checking Rear Brake Pads - KTM 85 SX 2011 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
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Changing basic position of the brake pedal *

The basic setting of the foot brake pedal can be changed by turning the end
stop roller [1]. Using the push rod [2], the free play on the foot brake pedal
must be set.
Measured on the outside, the foot brake pedal must have 3-5 mm of free play
before the push rod can move the piston in the brake cylinder (to be recog-
nised from the resistance on the foot brake pedal).
If this clearance is missing, pressure accumulates in the braking system and
the brake pads begin to rub. The braking system overheats and can fail com-
pletely in extreme cases.
3-5mm

Checking the rear brake fluid level

The reservoir for the rear disk brake is on the right side of the motorcycle on
the rear brake cylinder.
The brake fluid level may not drop below the upper edge A of the inspection
glass when the bike is in a horizontal position.
If the brake fluid level drops below the upper edge of the inspection glass,
this indicates that the brake system is either leaking or the brake shoes com-
A
pletely worn.

Refilling the rear brake fluid reservoir *

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Remove the screws [3] and take off the cover [4] and diaphragm [5].The brake
pistons must be pushed back to their basic position. Fill DOT 5.1 brake fluid
(e.g. Motorex Brake Fluid DOT 5.1) up to 10 mm (0.4 in) under the upper
edge of the reservoir.
Remount the diaphragm, cover and screws and actuate the foot brake lever
until you feel the point of pressure again. Wipe any overflowing or spilled brake
fluid off with water.
– Actuate the foot brake lever until you feel the point of pressure again.
– Never use DOT5 brake fluid! It is based on silicone oil and of a purple
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 rear brake pads

min.
The brake pads can be inspected from above. The thickness of the linings
may not be less than 1 mm (0.04 in).
1 mm
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 destroying the brake disc.
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