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MAINTENANCE WORK ON CHASSIS AND ENGINE
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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:
We recommend that you use Motorex DOT 5.1 brake fluid when you refill or
change the brake fluid. DOT 5. 1 brake fluid has a wet boiling point of 180°C
/ 356°F (25°C / 45°F higher than DOT 4) and is safer for high performance
applications. Brake fluid DOT 5.1 is a polyethylene glycol based fluid, amber-
colored and can be mixed with DOT 4 brake fluid. Do not, in any event, use
DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motor-
cycle gaskets and brake hoses are not designed for DOT 5 brake fluid.
Have the brake fluid changed at least once annually. If you wash your motor-
cycle 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 pro-
vided, 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