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MAINTENANCE WORK ON CHASSIS AND ENGINE
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Replacing the rear brake pads *
Dismount the rear wheel (see „Dismounting the rear wheel“).
Press the brake shoes apart with a suitable screwdriver to allow the brake pis-
tons to return to their basic position.
Remove the locking screw [1], unscrew the screw [2] and pull the brake shoes
out of the brake caliper.
Slide new brake shoes into the brake caliper a fasten with the screw [2].
Tighten the screw to 4 Nm and mount the locking screw [1].
Mount the rear wheel and actuate the foot brake lever until you can feel the
pressure point.
– It is very important to keep the brake disk free from oil and fatty matters.
Otherwise, the braking effect would be strongly reduced.
– After mounting, make sure the retaining bracket is in place.
– After working on the braking system, one must always actuate the hand
brake lever or foot brake lever, respectively so as to ensure that the brake
pads will lie against the brake disk and the pressure point is established.
Removing and installing front wheel
To remove the front wheel, jack the motorcycle up on its frame so that the
front wheel no longer touches the ground.
Loosen the collar screw [3].
Loosen the 2 clamping screws [4] on the fork fists.
Hold the front wheel, pull out the wheel spindle [5].
Remove front wheel carefully from the fork.
– Do not operate the hand brake when the front wheel has been dismounted.
– Make sure the brake disc is always on top when you lay down the wheel,
otherwise the brake disc can be damaged.
Insert the front wheel in the fork and adjust to the right position.
Mount the wheel spindle [5] and tighten the clamping screws on the right
fork leg slightly.Degrease the thread on the collar screw and apply Loctite 243.
Mount the collar nut and tighten to 40 Nm.
Take the motorcycle off the stand and bounce the fork hard a few times to
align the fork legs. Then tighten clamping screws to a max. torque of 10 Nm.
– If you don’t happen to have a torque wrench at hand, make sure you have
the tightening torque corrected by a KTM dealer as soon as possible. A
loose axle may lead to an unstable driving behavior of your motorcycle.
– After mounting the front wheel, keep operating the hand brake until the
pressure point returns.
– It is very important to keep the brake disk free from oil and fatty matters,
otherwise the braking effects would be strongly reduced.
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