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20
Chain wear
In order to check the chain wear, regard the following instructions:
Shift the gear into idling and pull the upper chain strand with approx. 10-15
kilogramm (33 lb) upwards (see figure). Now one can measure a space of
18 chain reels at the lower chain strand. The chain should be replaced at the
latest when a space of 272 mm (10,70 in) is measured. Chains do not
always wear off evenly, therefore repeat the measurement at different
places on the chain.
NOTE:
If you mount a new chain, the sprockets should also be replaced. New
chains wear faster if used on old used sprockets.
General informations about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series “float“. This means that the brake calipers
are not solidly attached to the caliper support. Thus, the brake pads are
always in optimum contact with the brake disc.
BRAKE PADS:
The motorcycles are delivered with organic brake pads and have also been
type-coded with these pads. Said pads are suitable for almost the entire
range of application of these motorcycles.
It is only for competitive racing in extremely dirty conditions (e.g., water in
combination with sand and mud) that we recommend brake pads that have
sintered linings. However, take notice of the fact that brake pads with sinte-
red linings have not been type-coded! Besides, they may cause greater wear
on the brake discs.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the 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 either the brake system has a leak or the brake pads are
completely worn down.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake systems with Shell Advance Brake 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 DOT 5 braking fluid. It is based on silicone oil and has a purple
color. Gaskets and brake hoses are not compatible with it.
BRAKE DISCS:
Wear reduces the thickness of the brake disc in the area of contact
1 with
the brake pads. At its thinnest spot
A, the brake disc must not be more
than 0.4mm thinner than its nominal dimension
B. The nominal dimension
can be gaged in a location beyond the area of contact with the brake pads.
Check wear in several spots.
ƽ
WARNING
ƽ
–BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM CONSTITUTE A SAFETY
HAZARD
. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON AS IT REACHES ITS
WEAR LIMIT
.
–A
S A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CARRIED OUT
BY A LICENSED
KTM MECHANIC.
Adjusting of free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjusting
screw
2. In this way, the position of the point of pressure (i.e., the
resistance you feel on the hand brake lever when the brake pads are
pressed against the brake disc) can be adjusted for any hand size.
!
CAUTION
!
A
T THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM. ONLY THEN MAY
THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED
(TO BE RECOGNIZED BY THE GREA-
TER RESISTANCE OF THE HAND BRAKE LEVER
). IF THIS FREE TRAVEL IS NOT PROVIDED,
PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT WHEEL BRAKE MAY
FAIL DUE TO OVERHEATING
.
15 KG
max. 272 mm
1 2 3
16 17 18
DOT
5.1
DOT
5
✓
✕
min. 3 mm
2
A
B
1