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MAINTENANCE WORK ON CHASSIS AND ENGINE »
General information on KTM disk brakes
BRAKE CALIPERS:
The front brake calipers [1] have 4 brake pistons each and are firmly con-
nected to the fork legs. The front brake disks are designed as "floating" brake
disks, i.e. they are not firmly connected to the front wheel.
The lateral balance ensures that the brake pads always have the best possi-
ble contact to the brake disk. Apply Loctite 243 to the screws [2] on the brake
caliper support and tighten to 45 Nm.
The rear brake caliper [3] has 1 brake piston and is designed as a "floating
brake caliper, i.e. it is not firmly connected to the brake caliper support. The
lateral balance ensures that the brake pads always have the best possible con-
tact to the brake disk.
FOR SAFETY REASONS, ALWAYS HAVE MAINTENANCE WORK AND REPAIRS TO THE
BRAKE SYSTEM PERFORMED BY AN AUTHORIZED KTM WORKSHOP.
A
1
2
3
4
BRAKE PADS:
Your motorcycle is equipped with sintered brake pads in the front and rear
and homologated accordingly. They guarantee maximum braking
performance.
Front brake pads: Toshiba TT 2172 HH
Rear brake pads: Toshiba TTH 38 GF
BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR-
IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE
PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN
DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER-
ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT
CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF-
FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS
AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY
WILL BE VOID.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not neces-
sary to top up the brake fluid. There is no reason to remove the reservoir cap
under normal conditions. If the brake fluid level drops below the minimum
either the brake system has a leak or the brake pads are completely worn down.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,
one of the best brake fluids that is 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. However, you should replace it as soon as possible
by DOT 5.1.
Never use DOT 5 braking fluid. It is based on silicone oil and has a purple
color. Gaskets and brake hoses are not compatible with it.
Brake fluid is exposed to a high thermal load and absorbs moisture from the
air, which lowers the boiling point. The brake fluid should therefore be changed
at the prescribed intervals.
HAVE THE BRAKE FLUID FOR THE FRONT AND REAR BRAKE CHANGED AT AN
AUTHORIZED KTM WORKSHOP EVERY 2 YEARS.
BRAKE DISCS:
Wear reduces the thickness of the brake disc in the area of contact [4] with
the brake pads. The brake disk should not be thinner than 4 mm (0.16 in) at
the weakest point [A]. Check the wear at several points.
BRAKE DISKS THAT ARE LESS THAN 4 MM (0.16 IN) THICK ARE A SAFETY HAZ-
ARD. HAVE WORN BRAKE DISKS REPLACED IMMEDIATELY.