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MAINTENANCE WORK ON CHASSIS AND ENGINE »
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].
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
– AFTER 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 cylin-
der (to be recognised from the resistance on the foot brake pedal).
IF 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 reservoir for the rear brake disk is located on the right side of the motor-
cycle on the rear brake cylinder.
No air bubble should be visible in inspection glass [A] when the vehicle is
parked in a vertical 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 *
Add brake fluid as soon as a bubble is visible in inspection glass [A].
To top up, remove screw [7]. Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid
DOT 5.1) up to the mark [B] on the inside of the reservoir and remount the
screw. Spilled brake fluid must be rinsed off with water.
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A
PURPLE 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.
– 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.
3-5mm
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1
2
2
1
2
4
3
6
5
A
B
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