Replacing The Front Brake Pads; Changing Basic Position Of The Brake Pedal - KTM 65 SX 2005 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
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Replacing the front brake pads *

Remove the front wheel (see front wheel chapter).
Press brake shoes apart with a suitable screwdriver to put the brake pistons
in their basic position.
Remove the lock washer [1] from the screw as well as fixing screw [2] and
take the brake shoes out of the brake caliper. Clean brake caliper thoroughly
with compressed air.
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2
Mount the right brake shoe and fix with screw. Mount the left brake shoe and
tighten the screw to 6 Nm. Mount the lock washer. Align brake shoes, mount
front wheel (see chapter: Mounting the front wheel).

Changing basic position of the brake pedal *

The basic setting of the foot brake pedal can be changed by turning the end
stop roller [3]. Using the push rod [4], the free play on the foot brake pedal
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 recog-
nised from the resistance on the foot brake pedal).
IF THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYS-
TEM AND THE BRAKE PADS BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS
AND CAN FAIL COMPLETELY IN EXTREME CASES.
3-5 mm
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
– HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST
ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER, RESPEC-
TIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE
DISK AND THE PRESSURE POINT IS ESTABLISHED.
– DO NOT UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL
HAVE TO BLEED THE BRAKE SYSTEM.
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