14 BRAKE SYSTEM 65 141 Checking free travel of hand brake lever Warning Danger of accidents Brake system feilure. = If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. TN] ~ Pithtte hae ate love frat and check roe tae! @ Z Free travel of hand brake lever zo ame Olam » Ifthe free travel does not meet specifications: — Adjust the basic position of the hand brake lever. (* p. 66) = Check the free travel ofthe hand brake lever. (€ p. 66) ~ Adjust the basic position of the hand brake lever with the adjusting screw @ to the rider's hand size. —O Info TH Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handleber. 60265412, The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do nat make any adjustments while riding! Wan Danger of accidents Brake system feilure. = Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding, = Avoid contact with skin and eyes, and keep out of the reach of children = Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. = Change the brake fluid of the front and rear brake according to the service schedule, Warning Environmental hazard Hazardous substances cause environmental damage. Warning Skin ivitation Brake fluid can cause skin irritation on contact. = Gil, grease, filters, uel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! Its silicone-based and purple in color. Oil seals and brake lines are not designed for DOT § brake fluid Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.14 BRAKE SYSTEM 6 = Move the brake fui reservoir mounted onthe handlebar toa horizontal positon. = Remove screns @ = Remove cover @ with membrane © = Check the brake uid level ‘Brake fluid level under top leval of con- | 5 mm (0.2 in) tainer » Ifthe brake fluid level does not meet specifications: = Add front brake fluid, (** p. 67) — Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water Warning Danger of accidents Brake system feilure. Ifthe brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding, In Brake fluid can cause skin iritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning. Danger of accidents Reduced braking efficiency dve to old brake fluid. = Change the brake fluid of the front and rear brake according to the service schedule, Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! I is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work = Check the front brake linings. (* p. 69) Main work = Move the brake fluid reservoir mounted on the handlebar toa horizontal position. = Remove screws @. ~ Remove cover @ with membrane @. = Correct the brake fluid level Guideline Brake fluid level under top level of con- | 5 mm (0.2 in) tainer Brake fluid DOT 4/ DOT 5.1 (* p. 150) = Posit n the cover with the membrane, Mount and tighten the screws. Info T Ciean up overtiowed or spilt brake fluid immediately with water.14 BRAKE SYSTEM 68 14.5 Changing the front brake uid Warning ‘Skin initation Brake fluid can cause skin itritation on contact. = Avoid contact with skin and eyes, and keep out of the reach of children = Wear suitable protective clothing and goggles. — If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning. Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. — Move the brake fluid reservoir mounted on the handlebar to a horizontal position. = Cover the painted parts. = Remove screws @. = Remove cover @ with membrane. = Draw the old brake fluid out of the brake fluid reservoir using a syringe and fil with fresh brake fluid Bleed syringe (50323050000) (* p. 157) Brake fluid DOT 4/ DOT 5.1 (> p. 160) = Mount bieeder cover @ Bleeder cover (00029013018) (* p. 154) = Connect the bleeding device. Bleeding device (00029013100) (* p. 154) = open shutoff valve @ Info T Fotlow the operating instructions of the bleeding device. ~ Ensure that the filling pressure is correctly set at pressure gauge @. If necessary, adjust the filling pressure at pressure regulator Guideline Filling pressure 2... 25 bar (29... 36 psi) ~ Palo dust cap @ ofthe brake caligerbleder screw. Connect the hose ofthe Dleeder bottle Bleeding device (00029013100) (*" p. 154) ~ Open bleder screw @ by approx. one-half tun, © Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles, 201630-10, = Tighten the bleeder screw. = Close shutoff vave @.14 BRAKE SYSTEM 69 = Open the bleeder screw again until no more brake fluid emerges, Info TThis prevents ovefiling of the brake fluid reservoir. = Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust cap. = Disconnect the bleeding device. Remove the bleeder cover, = Correct the brake fluid level to level @. Guideline Level @ (brake fluid level below top | 5 mm (0.2 in) edge of container) Brake fluid DOT 47 DOT 5.1 (* p. 150) = Position the cover with the membrane. Mount and tighten the screws. Info T ciean up overtiowed or spilt brake fluid immediately with water. = Check the hand brake lever for a firm pressure point. Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. = Change worn brake linings immediately. = Check the brake linings for minimum thickness @. Winimum tickness @) BT am 0.04 » If the minimum thickness is less than specified: = Change the front brake linings. (€* p. 70) = Check the brake linings for damage and cracking, >If damage or wear is encountered: = Change the tront brake linings. (** p. 70) Preparatory work = Raise the motorcycle with a lift stand. (* p. 10) = Remove the front wheel. (** p. 59) Main work ~ Remove the lack washer @. = Remove screw @. 00033-10, = Remove the brake linings. = Clean brake caliper and brake caliper support. 0002.0114 BRAKE SYSTEM 10 14.8 Instaling the front brake mings Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. = Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- ton and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the ori nal license. The vehicle na longer corresponds to the condition at delivery, and the warranty is no longer valid Preparatory work = Check the brake discs. ( p. 58) Main work = Insert new brake linings. ee mo Aways change the brake linings in pars. Ensure thatthe brake linings are correctly positioned in the retaining spring, 00032-01 = Mount and tighten screw @. Guideline Screw, brake linings Ne TONm (7.4 WFD = Mount took washer @ 00034-10 Finishing work = Install the front wheel. ( p. 60) Warning Skinititaion Brake fluid can cause skin iritation on contact. = Avoid contact with skin and eyes, and keep out of the reach of children = Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. = Change the brake fluid ofthe front and rear brake according to the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, ec., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicon-based and purple in color. il seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.14 BRAKE SYSTEM n Preparatory work = Raise the motorcycle with a litt stand. (#* p. 10) = Remove the front wheel. (Fp. 59) = Remove the front brake linings. (© p. 69) Main work = Move the brake fuid reservoir mounted onthe hanaleber to a heizontal positon = Remove scens @ = Remove cover @ with membrane © Press the brake piston back to its basic position and make sure that no brake fluid ‘overflows from the brake fluid reservoir. Install the front brake linings. ( p. 70) Correct the brake fluid level Guideline Brake fluid level under top level of con- | 5 mm (0.2 in) tainer Brake fluid DOT 4/ DOT 5.1 (* p. 180) ~ Position the cover with the membrane. Mount and tighten the screws. Info T Glean up overtiowed or spilt brake fluid immediately with water. Warning Danger of accidents Brake system failure. If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to ‘overheating. Adjust the free travel on foot brake lever according to specifications. = Disconnect spring @. = Move the foot brake lever back and forth between the end stop and the foot brake cylinder piston bracket and check free travel @. Guideline Free travel of foot brake lever 3... 5mm (0.12... 0.2 in) » Ifthe free travel does not meet specifications: = Adjust the free travel of the foot brake lever. (€ p. 71) ~ Attach spring @ Warning. Danger of accidents Brake system failure = If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to ‘overheating. Adjust the free travel on foot brake lever according to specifications = Detach the spring. = Loosen nut @. ~ Turn push rod @ until clearance @ is created Guideline Free travel of fot brake lever 3 Bmm (O12. 02) ~ Hola push rod @ and tighten nut @ = Attach the soring = Check whether the basic postion of the fot brake lever is suitable forthe rider.14 BRAKE SYSTEM n » When the basic position of the foot brake lever needs to be adjusted: = Adjust the basic position of the foot brake lever. (7p. 72) Warning Danger of accidents Brake system failure = If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to ‘overheating. Adjust the free travel on foot brake lever according to specifications = Detach the spring = Loosen nut @. = Turn back push rod @. = Loosen nut @. = Toadjust the basic position ofthe foot brake lever, turn screw @ accordingly Info The range of adjustment is limited. 601955-11 Hold screw @ and tighten nut @. Guidetine Remaining nuts, chassis ue 25 Nm (18.4 tor A) Check the free travel of the foot brake lever. (#* p. 71) Guideline Free travel of foot brake lever 3... 5mm (0.12... 0.2 in) » Ifthe free travel at the foot brake lever does not meet specifications: — Adjust the free travel of the foot brake lever. (* p. 71) ~ attach spring @. Warning Danger of accidents Failure of the brake system. Ifthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding Warning Danger of accidents Reduced braking efficiency due to old brake fluid. Change the brake fluid of the front and rear brake according to the service schedule, = Stand the vehicle upright ~ Check the brake fluid level in te viewer @ > When an air buble is visible in the viewer @ = Add rear brake fluid. (* p. 73)14 BRAKE SYSTEM B 14.14 Adding rear brake fui Warning Danger of accidents Failure of the brake system. = Ifthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding Warning Skinittaion Brake fluid can cause skin irritation on contact. = Avoid contact with skin and eyes, and keep out ofthe reach of children = Wear suitable protective clothing and goggles ~ If brake fluid comes into contact withthe eyes, flush the eyes thoroughly with water and consulta physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid = Change the brake uid of the front and rear brake according tothe service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, uel, cleaners, brake fluid ec., should be disposed of as stipulated in applicable regulations © Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work = Raise the motorcycle with a lift stand. (7 p. 10) = Check the rear brake linings. (7 p. 75) Main work = Remove serous @. Take off cover @ with washer @ and membrane @. = Add brake fluid to level Guideline Dimension @ (brake fluid level below | 10 mm (0.39 in) top edge of container) Brake fluid DOT 4/ DOT 5.1 (* p. 180) Position the membrane and the cover with the washer. Mount and tighten the screws. Info T Glean up overtiowed or spilt brake fluid immediately with water Finishing work — Remove the motorcycle from the lft stand. (€ p. 10)14 BRAKE SYSTEM 4 14.15 Changing the rear brake uid Warning (AX sin titation Brake fluid can cause skin irritation on contac. = Avoid contact with skin and eyes, and keep out of the reach of children = Wear suitable protective clothing and goggles. — If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning. Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, uel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. = Cover the painted parts, = Remove screws . Take off cover @ with washer and membrane. = Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid, Bleed syringe (50329050000) (* p. 157) Brake fluid DOT 4/ DOT 5.1 (> p. 150) = Mount bieeder cover @ Bleeder cover (00029013012) (* p. 154) = Connect the bleeding device. Bleeding device (00029013100) (* p. 154) = open shutoff valve @. Info I Fotiow the operating instructions ofthe bleeding device ~ Ensure that the filling pressure is correctly set at pressure gauge @. If necessary, adjust the filling pressure at pressure regulator Guideline Filling pressure 2... 25 bar (29... 36 psi) = Pull off dust cap @ of the Bleeder screw. Connect the hose of the Bleeder bottle [Bleeding device (ouas0Is10N p15) ——SOSCS~S« = Open bleeder screw @ by approx. one-half turn, Info Bleed unti fresh brake fluid emerges from the bleeder bottle hose without bubbles. 20163310] ~ Tighten the bleeder screw. = Close shut tt ave © = Open the bleeder screw again until no mare brake fluid emerges.14 BRAKE SYSTEM 8 Info T This prevents overiting ofthe brake fluid reservoir. = Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust cap. = Disconnect the bleeding device. Remove the bleeder cover, ~ Correct the brake fluid level to level @. Guideline Level @ (brake fluid level below top | 10 mm (0.39 in), edge of container) Brake fluid DOT 4/ DOT 6.1 (* p. 160) = Position the membrane and the cover with the washer. Mount and tighten the screws. Info Ty clean uy ertoned or spit rake uid inmecitty wi water = Check the foot brake lever fora firm pressure point. Warning Danger of accidents Reduced braking efficiency cause by worn brake linings. = Change worn brake linings immediately. ~ Check the brake linings for minimum thickness @. Minimum trikes @) Blam 004m » If the minimum thickness is less than specified: = Change the rear brake linings. (** p. 76) = Check the brake linings for damage and cracking, >If damage or wear is encountered: = Change the rear brake linings. (*" p. 76) Warning Danger of accident rake system failure — Maintenance work and repairs must be carried out professionally. Preparatory work = Raise the motorcycle with a lift stand. (#* p. 10) — Remove the chain guard. (© p. 47) = Remove the rear wheel. (* p. 60) Main work = Remove lock washer @. = Remove screw @14 BRAKE SYSTEM 18 = Remove the brake linings. = Clean brake caliper and brake caliper support. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. = Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. f brake linings are used that differ from the originals, there is no guarantee that they comply with the origi= nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid Preparatory work = Check the brake discs. (* p. 58) Main work = Insert new brake linings, Info Aways change the brake linings in pairs. Ensure that the brake linings are correctly positioned in the retaining spring. = Mount screw @. Guideline Serew, brake linings M6 TON (7.410 = Mount tok washer @. = stall the rear whee. (© p. 61) = Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there isa pressure point. Warning Skin ittation Brake fluid can cause skin irritation on contact. = Avoid contact with skin and eyes, and keep out ofthe reach of children = Wear suitable protective clothing and goggles. = If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. = Change the brake fluid of the front and rear brake according to the service schedule,14 BRAKE SYSTEM n Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicon-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work = Raise the motorcycle with a lit stand. (F p. 10) = Remove the chain guard, (* p. 47) = Remowe the rer wneel. (* p. 60) = Remove the rear brake linings. ( p. 75) Main work = Remove serews @. ~ Toke off cover @ with washer @ and membrane @. Press the brake piston back to its basic position and make sure that no brake fluid ‘overflows from the brake fluid reservoir. = Install the rear brake linings. ( p. 76) = Add brake fluid to level Guideline Dimension @ (brake fluid level below | 10 mm (0.39 in) top edge of container) Brake fluid DOT 4/ DOT 5.1 (* p. 160) = Position the membrane and the cover with the washer. Mount and tighten the screns. © Info Clean up overflowed or spilt brake fluid immediately with water.