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33
Replacing the front brake pads *
Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips
1 and pull out bolt 2. Remove brake pads
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
sliding metal-sheet
3 in the caliper support and of the leaf spring 4.
ƽ
WARNING
ƽ
–I
TISVERY 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.
–
AFTER WORKING ON THE BRAKING SYSTEM
,
ALWAYS ACTUATE THE HAND BRAKE LEVER
OR FOOT BRAKE LEVER
,
RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE
AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED
.
Changing the basic position of the foot brake pedal *
The basic position of the foot brake pedal can be altered by turning the stop
screw
5. The free play at the foot brake pedal must then be adjusted by
means of the piston rod
6.
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).
!
CAUTION
!
I
F THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM
WHEN DRIVING
, CAUSING THE REAR WHEEL TO BRAKE.THE BRAKING SYSTEM OVERHEATS
AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES
.
Checking the rear brake fluid level
The brake fluid reservoir of the rear disc brake is located on the right side of
the motorcycle next to the kickstarter. The brake fluid level must not drop
below the ”MlN” marking when the vehicle is in an upright position.
ƽ
WARNING
ƽ
I
FTHE 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 AUTHO-
RIZED KTM DEALER IMMEDIATELY.
Refilling the rear brake fluid reservoir *
For this purpose, it is recommended to remove screw 7 and to pull the
brake fluid reservoir outwards. Now the screw cap
8 and the rubber boot
9 can be removed. Add brake fluid DOT 5.1 (Shell Advance Brake DOT
5.1) until the brake fluid level reaches the ”MAX” mark, then mount the
screw cap together with the rubber boot. Return the brake fluid reservoir to
its original position and fix it with the screw. The connecting hose between
the reservoir and the foot brake cylinder must be carefully positioned, pre-
venting kinks and keeping a safe distance between the hose and the
exhaust pipe. Spilled brake fluid must be rinsed off with water.
ƽ
WARNING
ƽ
–NEVER USE DOT5 BRAKE FLUID! ITISBASED ON SILICONE OIL AND OF A PURPLE
COLOR
. SEALS 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. AVOID CONTACT WITH SKIN AND EYES. IF
YOU GET BRAKE FLUID IN YOUR EYES
, RINSE WITH PLENTY OF WATER AND CONSULT A
DOCTOR
.
!
CAUTION
!
–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.
1
1
2
3
4
2
3-5mm
8
9
5
6
7