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24
MAINTENANCE WORK ON CHASSIS AND ENGINE »
Remove the safety device [1], knock out the guide pin [2] from the brake caliper
with a drift towards the chain wheel and remove the brake pads. Carefully
clean the brake caliper with compressed air and check the sleeves of the guide
pins for damage.
Press both brake shoes into the brake caliper and fix with bolt [2]. Mount the
locks [1]. Tighten bolt [2] to 5 Nm (3,7 ft.lb).
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
– 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 PRES-
SURE POINT IS ESTABLISHED.
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1
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4
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6
Dismounting and mounting the 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 2 clamping screws [3] on the left side of the fork fists.
Loosen and remove the collar nut [4], loosen the clamping screews [5] on the
right side of the fork fist.
Hold the front wheel, pull out the wheel spindle [6].
Carefully remove the front wheel 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.
To install the front wheel, lift it into the fork, position and mount the axle
shaft. Mount the collar nut [4], tighten the clamping screws [5] on the right
fork leg axle passage to prevent the axle shaft from turning and tighten the
collar nut to 30 Nm (22,14ft.lb).
Loosen the clamp screws on the right fork leg. Take the motorcycle down from
its stand. Press the front wheel brakes and push down on the fork a few times
vigorously so that the fork legs come into alignment.
Only after this has been accomplished, tighten the clamp screws on both fork
legs with 10Nm (7ft.lbs)
– 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 BEHAV-
IOR OF YOUR MOTORCYCLE.
– TIGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL
SPINDLE MAY LEAD TO AN UNSTABLE 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.