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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:
KTM fills the brake system with ”Shell Advance Brake 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.
ƽ
WARNING
ƽ
H
AVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR
MOTORCYCLE OFTEN
, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.
B
RAKE 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. At their thinnest point A, the brake
discs must not be more than 0.40 mm (0.016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location
B outside
the contact face. Check wear in several locations.
ƽ
WARNING
ƽ
–A
BRAKE DISK WORN DOWN 0.40 MM (0.016 IN) OR MORE IS A SAFETY RISK. HAVE
THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT
.
–H
AVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA 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
adjustment.
!
CAUTION
!
A
TTHE 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
.
Checking/refilling the front brake fluid level *
Put the hand brake cylinder in a horizontal position, remove screws 5 and
cover
6 with diaphragm 7. If necessary, refill DOT 5.1 (e.g. Shell Advance
Brake 5.1) brake fluid up to 5 mm (0.2 in) under the upper edge of the tank.
Remount the diaphragm, cover and screws. Wash off any overflowing or
spilled brake fluid with water.
ƽ
WARNING
ƽ
–NEVER
USE DOT 5 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
!
–D
ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE
PAINT REMOVER
.
–U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
DOT
5.1
DOT
5
✓
✕
min. 2 mm
2
4
3
5 mm
6
5
7
A
B
1