Checking The Rear Brake Pads; Replacing The Rear Brake Pads; Dismounting And Mounting The Front Wheel - KTM 250 EXC RACING 2004 Owner's Manual

min.
1 mm
34
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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
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 *

1
Push the brake caliper toward the chain wheel in order to move the
brake piston into its basic position. Remove the clips
and remove the brake pads. Thoroughly clean the brake caliper with
compressed air and check the sleeves of the guide bolts for damage.
Insert the left brake pad into the brake caliper and secure it with the bolt.
Insert the right brake pad and push the bolt
2
the stop. Reattach clips .
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 CLIPS 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

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
the 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 27 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
.
CAUTION
2
, pull out the bolt
3
into the brake caliper up to
.
,
ALWAYS ACTUATE THE HAND BRAKE
RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL
4
on the left side of the fork fists.
5
., loosen the clamping screews
7
.
CAUTION
.
, tighten the clamping screws
!
,
.
3
,
.
.
.
6
on
!
,
6
on the right