General Information About Ktm Disc Brakes - KTM 640 DUKE II 2005 Owner's Manual

MAINTENANCE WORK ON CHASSIS AND ENGINE
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General information about KTM disc brakes

BRAKE CALIPERS:
The front brake caliper [1] has 4 brake pistons and is rigidly connected to the
fork leg. The rear brake caliper has one brake piston and „floats", which means
that it is not rigidly connected to the brake caliper support. The resulting lat-
eral adjustment ensures that the brake pads [2] optimally rest against the
brake disk at any time.Secure the screws of the caliper support with Loctite
243 and tighten to 45 Nm (33,2 ft.lb).
BRAKE PADS:
The brake pads are fitted with FERODO ID450 organic lining at the front with
TOSHIBA TT 2261 FF sintered lining at the back.
2
These linings provide an optimal combination of dosing, brake performance
and life cycle. The lining type is stated on the back of the brake pad and also
recorded in the homologation papers.
The thinnest point of the lining must not be thinner than 1 mm.
A
BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR-
B
IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE
PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN
DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER-
ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT
CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF-
FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS
AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY
WILL BE VOID.
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BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face [3] of the brake pads decreases. At their thinnest point [A], the brake
discs must not be more than 0.4 mm (0.016 in) thinner than the pad's nom-
inal thickness. Measure the nominal thickness in a location [B] outside the
contact face. Check wear in several locations.
– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,4 MM (0,016 IN)
CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI-
ATELY AS SOON AS THEY REACH THE WEAR LIMIT.
– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER
BRAKE FLUID:
KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,
one of the best brake fluids that is currently available. We recommend that
you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an
amber color. If you do not have any DOT 5.1 for refilling, you may use DOT
4 brake fluid. However, you should replace it as soon as possible by DOT 5.1.
Never use brake fluid DOT 5. The color of this silicon oil-based product is
purple red. The gaskets and brake hoses of KTM motorcycles are not designed
for DOT 5 brake fluid!
CHANGE BRAKE FLUID AT LEAST ONCE A YEAR. IF THE MOTORCYCLE IS BEING
WASHED VERY OFTEN, CHANGE BRAKE FLUIF MORE OFTEN. BRAKEFLUID HAS
THE ABILITY TO ADMIT WATER; THEREFORE, STEAM BUBBLES CAN FORM IN
„OLD" BRAKE FLUID AT RELATIVELY LOW TEMPERATURES THUS CAUSING THE
BRAKE SYSTEM TO FAIL.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been designed
in such a way that even if the brake pads are worn it is not necessary to top
up the brake fluid. If the brake fluid level drops below the minimum level
either the brake system has a leak or the brake pads are completely worn. In
this case, consult an authorized KTM dealer immediately.
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