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MAINTENANCE WORK ON CHASSIS AND ENGINE
28
3
4
min.
1 mm
min. 3 mm
1
2
5 mm
Adjusting of free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjusting
screw [1]. 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.
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.12 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 BRAK-
ING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.
Checking of 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 reser-
voir in a horizontal position, the brake fluid level should not go below middle
of the glass.
– IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN.
IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.
– HAVE THE BRAKE FLUID CHANGED AT AN AUTHORIZED KTM WORKSHOP
EVERY 2 YEARS.
Refilling the front brake fluid reservoir *
It is not necessary to refill brake fluid under normal conditions (see General
information on KTM disk brakes).
However, the brake fluid must be refilled as soon as the brake fluid level reaches
the MIN mark.
Remove the screws [2] and the cover [3] with the rubber boot [4]. Push the
front brake caliper pistons all the way back, demounting the front wheel if
necessary. Move the hand brake cylinder in a horizontal position and fill DOT
5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to 5 mm (0.2 in) under the
top edge of the reservoir. Remount the rubber boot, cover and screws. Wash
off any overflowing or spilled brake fluid with water. Actuate the front brake
until you feel the point of pressure.
– ACTUATE THE FRONT BRAKE UNTIL YOU FEEL THE POINT OF PRESSURE.
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR-
PLE 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 the front brake pads
The brake pads can be inspected from below. The linings must be at least
1 mm (0.04 in) thick.
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 WHEN THE LINING IS PARTLY OR
COMPLETELY WORN OFF, THE STEEL PARTS ON THE BRAKE PADS WILL GRIND
AGAINST THE BRAKE DISKS. THIS SIGNIFICANTLY DECREASES THE BRAKING
EFFECT AND DESTROYS THE BRAKE DISKS.
»
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