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MAINTENANCE WORK ON CHASSIS AND ENGINE
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General information about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series use a „floating“ mount. This means that the
brake calipers are not solidly attached to the caliper support, which enables
them to „float“ for maximum braking contact. Secure the screws of the caliper
support with Loctite 243 and tighten to 25 Nm.
BRAKE PADS:
The brake pads are fitted with TOSHIBA TT 2701 HHB sintered lining at the
front and TOYO B 143 FF sintered lining at the back. These linings provide
an optimal combination of dosing, brake performance and life cycle. The lin-
ing type is stated on the back of the brake pad and also recorded in the homolo-
gation papers.
BRAKE DISCS:
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 (front) / 3.50 mm (rear) 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 (front) / 3.50 mm (rear) is
a safety risk. Have the brake disk replaced as soon as it reaches the serv-
ice limit.
– Have any repairs on the brake system be performed by a KTM dealer.
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. If the brake fluid level drops below the mini-
mum 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 appli-
cations. Brake fluid DOT 5.1 is a polyethylene glycol based fluid, amber-col-
ored 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 motorcycle
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.