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MAINTENANCE WORK ON CHASSIS AND ENGINE »
General information about KTM disc brakes
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs for the front brake is designed such that it does not
need to be refilled, even if the brake shoes are worn. 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.
BRAKE FLUID:
KTM fills the brake system with ”Motorex Brake Fluid DOT 5.1”, one of the
best brake fluids 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. DOT 4
shown on the lid means minimum standard. However, you should replace it
as soon as possible by DOT 5.1.
HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR
MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE
FREQUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR
POCKETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES,
CAUSING THE BRAKE SYSTEM TO FAIL.
BRAKE DISC:
Due to wear, the thickness of the brake disc in the area of the contact
face [1] of the brake pads decreases. The brake disk must be at least 2.50
mm thick at the thinnest point [A]. Check the thickness of the brake disk at
several points.
– A BRAKE DISK WORN DOWN TO LESS THAN 2.50 MM IS A SAFETY RISK. HAVE
THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT.
– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM
DEALER.
BRAKE CALIPERS:
Secure the screws on the brake caliper with Loctite 243 and tighten to a torque
of 20 Nm.
Setting the basic position and play of the hand brake lever *
You can adjust the basic position of the hand brake lever to fit your child's
hand by turning stop screw [2]. Afterwards, be sure to adjust the play of the
hand brake lever to 2 mm (0.08 in)with the adjusting screw [3]. To adjust,
remove covering cap [4]. Replace the covering cap after making the adjust-
ment.
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 2 MM (0.08 IN).
ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE
RECOGNIZED BY THE GREATER 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.
1
A
min. 2 mm
2
3
4