Checking The Rear Brake Pads; Replacing The Rear Brake Pads; Dismounting And Mounting The Front Wheel - KTM 250 SX 2003 Owner's Handbook Manual

min.
1 mm
26
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3
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4
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6

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).
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

Replacing the rear brake pads *

1
Press the brake caliper in the direction of the chain wheel for the brake
piston to reach its basic position. Remove the safety device
3
guide pin from the brake caliper with a drift towards the chain wheel and
remove the brake pads. Carefully clean the brake caliper with compressed air
and check the sleeves of the guide pins for damage.
Slide the left brake pad into the brake caliper and fix it with the pin. Slide in
the right brake pad and knock the bolt
2
safety device .
WARNING
– I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS
O ,
THERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED
– A ,
FTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY
– A
FTER WORKING ON THE BRAKING SYSTEM
BRAKE LEVER OR FOOT BRAKE LEVER
PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED

Dismounting and mounting the front wheel

To remove the front wheel, jack the motorcycle up on its frame so that the
front wheel no longer touches the ground.
Loosen the 2 clamping screws
Loosen and remove the collar nut
right side of the fork fist.
Hold the front wheel, pull out the wheel spindle
NOTE: The wheel spindle can be easily removed if you slightly revolve it with
a ring spanner (SW 21 mm).
Carefully remove the front wheel from the fork.
!
– D
O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN
.
DISMOUNTED
– M
AKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL
OTHERWISE THE BRAKE DISC CAN BE DAMAGED
To install the front wheel, lift it into the fork, position and mount the axle
5
shaft. Mount the collar nut
fork leg axle passage to prevent the axle shaft from turning and tighten the
collar nut to 40 Nm (30ft.lb).
Loosen the clamp screws on the right fork leg. Take the motorcycle down
from its stand. Press the front wheel brakes and push down on the fork a few
times vigorously so that the fork legs come into alignment.
Only after this has been accomplished, tighten the clamp screws on both
fork legs with 10 Nm(7 ft. lbs).
. F
OR YOUR OWN SAFETY DON
.
CAUTION
2
3
in as far as it will go. Mount the
,
ONE MUST ALWAYS ACTUATE THE HAND
,
RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE
4
on the left side of the fork fists.
5
, loosen the clamping screews
7
.
CAUTION
.
, tighten the clamping screws
1 ,
MM
'
T PUT OFF
!
,
.
, knock out the
.
.
.
.
6
on the
!
,
6
on the right