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MAINTENANCE WORK ON CHASSIS AND ENGINE
2
General information about KTM disc brakes
BRAKE CALIPERS:
If the front brake caliper is removed, the screws must be secured with Loctite
243 when mounted and tightened to 20 Nm.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not neces-
sary to top up the brake fluid. If the brake fluid level drops below the mini-
mum level either the brake system has a leak or the brake pads are completely
worn. In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake system with "Motorex Brake Fluid DOT 5.1", one of the
best brake fluids currently available. We recommend that you continue to use
it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. If you
do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid. DOT 4
shown on the lid means minimum standard. However, you should replace it
as soon as possible by DOT 5.1.
HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR
MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE
FREQUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR
POCKETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES,
CAUSING THE BRAKE SYSTEM TO FAIL.
BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face [1] of the brake pads decreases. At their thinnest point A, the brake discs
must not be more than 0.40 mm (0.016 in) thinner than the pad's nominal
A
thickness. Measure the nominal thickness in a location B outside the contact
B
face. Check wear in several locations.
– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.40 MM (0.016 IN)
CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI-
ATELY AS SOON AS THEY REACH THE WEAR LIMIT.
– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM
DEALER.
1
Adjusting free travel of the hand brake lever
Free travel of the hand brake lever may be readjusted by using the adjust-
ment screw [2]. In this way, the position of the point of pressure (i.e. the resist-
ance you feel on the hand brake lever when the brake pads are
pressed against the brake disc) can be adjusted for any hand size.
min. 3 mm
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN).
ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE
RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS
FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING
SYSTEM, AND THE FRONT-WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.
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