Replacing The Front Brake Pads; Changing The Basic Position Of The Foot Brake Pedal; Checking The Rear Brake Fluid Level; Refilling The Rear Brake Fluid Reservoir - KTM 250 EXC RACING 2004 Owner's Manual

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3-5mm
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B
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Replacing the front brake pads *

1 Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips
from the brake caliper. Clean the brake caliper and the brake caliper support
with compressed air. Check the sleeves of the guide bolts for damage, and
grease guide bolts if necessary.
Mount the right brake pad and fix it with the bolt. Mount the left brake pad
and insert the bolt until it stops. Mount the clips.
When mounting the brake pads, be sure to check for correct fit of the
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sliding metal-sheet
– 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
LEVER OR FOOT BRAKE LEVER
LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED
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Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop
5
screw . The free play at the foot brake pedal must then be adjusted by
means of the piston rod
Measured on the outside, the foot brake pedal must have 3-5 mm
(0.12–0.20 in) of free play before the piston rod can move the piston in the
brake cylinder (to be recognised from the resistance on the foot brake
pedal).
!
I
F THIS FREE PLAY IS NOT PRESENT
,
WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE
AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES

Checking the rear brake fluid level

The reservoir for the rear brake disk is located on the right side of the
motorcycle on the rear brake cylinder.
No air bubble should be visible in inspection glass
parked in a vertical position.
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
RIZED DEALER IMMEDIATELY

Refilling the rear brake fluid reservoir *

Add brake fluid as soon as a bubble is visible in inspection glass
To top up, remove screw
Fluid DOT 5.1) up to the mark
unt the screw. Spilled brake fluid must be rinsed off with water.
– N DOT5
EVER USE
. 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
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DOCTOR
!
– D '
ON T LET BRAKE FLUID GET IN CONTACT WITH PAINT
.
REMOVER
– U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER
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and pull out bolt
in the caliper support and of the leaf spring
WARNING
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ALWAYS ACTUATE THE HAND BRAKE
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RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL
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CAUTION
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THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM
.T
HE BRAKING SYSTEM OVERHEATS
.
WARNING
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N THIS CASE
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. Fill DOT5.1 brake fluid (e.g. Motorex Brake
B
on the inside of the reservoir and remo-
WARNING
! I
BRAKE FLUID T IS BASED ON SILICONE OIL AND OF A PURPLE
.
. A
VOID CONTACT WITH SKIN AND EYES
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RINSE WITH PLENTY OF WATER AND CONSULT A
CAUTION
2
. Remove brake pads
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!
A
when the vehicle is
, -
CONSULT AN AUTHO
A
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. I
F
!
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IT IS AN EFFECTIVE PAINT
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