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MAINTENANCE WORK ON CHASSIS AND ENGINE
2
1
4
min.
1 mm
Changing the basic position of the foot brake pedal*
The basic position of the foot brake pedal can be altered by turning the stop
A
roller [1]. The free play at the foot brake pedal must then be adjusted by means
of the piston rod [2].
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 cylin-
der (to be recognised from the resistance on the foot brake pedal).
To keep the stop roller from turning while tightening, insert a hexagon wrench
in bore [A].
IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE
3-5mm
BRAKE SYSTEM WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE
PADS.THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME
Checking the rear brake fluid level
The reservoir for the rear disc brake is located on the left-hand side of the
vehicle next to the carburetor carburetor connection boot. The brake fluid level
may not drop below the „MlN" marking when the vehicle is in an upright
position.
IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE,
CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.
Refilling the rear brake fluid reservoir*
When the brake fluid level has dropped to the MIN mark, you need to refill
the brake fluid reservoir.
For easier access to the brake fluid reservoir it is recommended to remove the
hexagon screw [3]. Then move the container outwards as indicated in the illus-
tration. Remove plug [4] with rubber boot [5] and add brake fluid DOT 5.1
(Motorex Brake Fluid DOT 5.1) up to the „MAX" mark. Replace rubber boot
and plug. Overflown or spilled brake liquid must be rinsed off with water. Mount
the screw and fix the brake fluid reservoir to the frame, always making sure
to prevent kinks in the connecting hose.
3
– 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
5
– 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 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).
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 SO THAT THE LINING IS PARTLY
OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL
RUB AGAINST THE BRAKE DISC, IMPARING THE BRAKING EFFECT AND DESTROY-
ING THE BRAKE DISC.
»
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