Adjusting The Free Travel At The Hand Brake Lever; Checking The Brake Fluid Level - Front Brake; Refilling The Front Brake Fluid Reservoir; Checking The Front Brake Pads - KTM 250 SX 2003 Owner's Handbook Manual

24
3
min.
1 mm
min. 3 mm
1
2
4
5 mm

Adjusting the free travel at the hand brake lever

Free travel at the hand brake lever may be readjusted by using adjustment
1
screw . In this way, the position of the point of pressure (i.e. the resis-tance
you feel on the hand brake lever when the brake pads are pressed against
the brake disc) can be adjusted for any hand size.
!
A ,
T THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE
MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED
GREATER RESISTANCE OF THE HAND BRAKE LEVER
PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM
.
FAIL DUE TO OVERHEATING

Checking the brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the
handlebar and the reservoir is provided with an inspection glass. With the
reservoir in a horizontal position, the brake fluid level should not drop below
the middle of the glass.
WARNING
I
F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN
KTM
AUTHORIZED DEALER IMMEDIATELY

Refilling the front brake fluid reservoir *

2
Loosen screws and remove lid
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (e.g.
Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.
WARNING
– N DOT5
EVER USE BRAKE FLUID
. S
COLOR EALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT
– S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN
– B
RAKE FLUID CAN CAUSE SKIN IRRITATION
YOU GET BRAKE FLUID IN YOUR EYES
DOCTOR
!
– D '
ON T LET BRAKE FLUID GET IN CONTACT WITH PAINT
– U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER

Checking the front brake pads

The brake pads can be inspected from below. The linings must be at least
1 mm (0.04 in) thick.
WARNING
A
T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN
OTHERWISE THEY COULD LEAD TO BRAKE FAILURE
HAVING YOUR BRAKE PADS CHANGED
!
I
F 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
CAUTION
3 (0.1
MM
(
TO BE RECOGNIZED BY THE
). I
F THIS FREE TRAVEL IS NOT PROVIDED
,
AND THE FRONT
. I
N THIS CASE
.
3 4
and membrane .
! I
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
CAUTION
,
IT IS AN EFFECTIVE PAINT REMOVER
. F
OR YOUR OWN SAFETY DON
.
CAUTION
!
). O
IN NLY THEN
,
-
WHEEL BRAKE MAY
,
CONSULT AN
.
. I
F
!
.
.
1 ,
MM
'
T PUT OFF
!
,
.