Changing The Basic Position Of The Brake Pedal; Checking The Rear Brake Pads; Replacing The Rear Brake Pads - KTM 625 SXC 2003 Owner's Manual

1
2
min.
1 mm
30
A
3-5mm
3
4
5

Changing the basic position of the brake pedal *

The basic setting of the foot brake pedal can be changed by turning the end
1
stop roller . Using the push rod
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
recognised from the resistance on the foot brake pedal).
To keep the stop roller from turning while tightening, insert a hexagon
A
wrench in bore .
!
I ,
F THIS CLEARANCE IS MISSING PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND
THE BRAKE PADS BEGIN TO RUB
.
COMPLETELY IN EXTREME CASES

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
1 ,
MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE
'
DON T PUT OFF 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 *

3
Press brake caliper in direction of chain wheel for the brake piston to
reach its basic position. Remove safety device
from the brake caliper with a drift towards the chain wheel and remove
brake pads. Carefully clean the brake caliper with compressed air and check
sleeves of the guide pins for damage.
Slide left brake pad into the brake caliper and fix it with the pin. Slide in the
right brake pad and knock the bolt in as far as it will go. Mount safety
device 4 .
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
– H
AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM
ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE
.
POINT IS ESTABLISHED
2
, the free play on the foot brake pedal
CAUTION
. T
HE BRAKING SYSTEM OVERHEATS AND CAN FAIL
. F
OR YOUR OWN SAFETY
.
CAUTION
4
, knock out the guide pin
,
,
RESPECTIVELY SO AS TO
!
!
,
.
5
.
.
.
ONE MUST ALWAYS