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21
MAINTENANCE WORK ON CHASSIS AND ENGINE
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General information about KTM disc brakes
BRAKE CALIPERS:
If the front brake caliper is removed, the screws must be secured with Loctite
243 when mounted and tightened to 25 Nm.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on 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
applications. Brake fluid DOT 5.1 is a polyethylene glycol based fluid, amber-
colored 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 motor-
cycle 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.
BRAKE DISCS:
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.
– Brake discs suffering from wear greater than 0.40 mm (0.016 in) consti-
tute a safety risk. Have the brake discs replaced immediately as soon as
they reach the wear limit.
– Have any repairs on the brake system be performed by a KTM dealer.
Adjusting free travel of the hand brake lever
Free travel of the hand brake lever may be readjusted by using the adjust-
ment screw [2]. In this way, the position of the point of pressure (i.e. the resist-
ance you feel on the hand brake lever when the brake pads are
pressed against the brake disc) can be adjusted for any hand size.
At the hand brake lever, free travel must at least be 3 mm (0.1 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.
A
B
1
min. 3 mm
2