14 BRAKE SYSTEM n 141 Checking the free travel ofthe hand brake lever Warning Danger of accidents The brake system fails inthe event of overheating If there is no ree travel on the hand breke lever, pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification. ~ Push the hand brake lever forward and check free travel @). Free travel of hand brake lever 23mm (20.12 in) ~~ Xx > the re trv does nat mes pectcatos = Adjust the free travel of the handbrake lever. (® p. 72) 1wo1029-10) = Check the free travel ofthe hand brake lever. (>. 72) ~ Adjust the fee travel of he handbrake lever wth adjustment screw @ © Info HTurn the adjusting screw clockwise to reduce free travel. The pressure point moves away from the handlebar. Turn the adjusting screw counterclockwise to increase free travel. The pres- sure point moves towards the handlebar. The range of adjustment is limited. £00475.10 Turn the adjusting screw by hand only, and do not apply force. Do nat make any adjustments while riding! Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fall If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down, = Check the brake system and do not continue riding until the problem is eliminated, Warning Danger of accidents Old brake fluid reduces the braking effect. ~ Make sure that brake fluid forthe front and rear brake is changed in accordance withthe service schedule. = Move the brake fui reservoir mounted on the handlebar toa horizontal positon. = Check the brake fluid level in viewer @) 2 Ifthe brake fui has dropped below marking @ = Add front brake fluid (© p. 73)14 BRAKE SYSTEM n Warning Danger of accidents An insufficient brake fluid level wll cause the brake system to fall It the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings ae worn down, = Check the brake system and do not continue riding until the problem is eliminated Warning Skinitttation Brake fluid causes skin irritation = Keep brake fluid out ofthe reach of children Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact with the skin the eyes ar clothing. = Consult @ doctor immediatly if brake fluid has been swallowed. — Rinse the affected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. = If brake fluid spills onto your clothing, change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect. ~ Make sure that brake fluid fr the front and rear brake is changed in accordance with the service schedule, Warning Environmental hazard Hazardous substances cause environmental damage. = Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info Never use DOT 5 brake fluid. itis 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. Only use clean brake fluid from a sealed container. Preparatory work = Check the front brake linings. (© p. 75) Main work = Mave the brake fluid reservoir mounted on the handlebar to a horizontal position. = Remove scens @ = Remove cover @ with membrane © = Add brake fluid to level @. Guideline Level @ (brake fluid level below reser- | 5 mm (0.2 in) voir rim) Brake fluid DOT 4/ DOT 5.1 (=p. 168) = Position the cover with the membrane. Mount and tighten the screws. Info T Clean up overflowed or spilled brake fluid immediately with water.14 BRAKE SYSTEM ™ Warning ‘Skin ination Brake fluid causes skin irritation ~ Keep brake fluid out of the reach of children. ~ Wear suitable protective clothing and safety glasses. — Do not allow brake fluid to come into contact withthe skin, the eyes or clothing. = Consult @ doctor immediatly if brake fluid has been swallowed. —_ Rinse the affected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult a doctor if brake uid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing Warning Environmental hazard Hazardous substances cause envirenmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. — Mave the brake fluid reservoir mounted on the handlebar to a horizontal position. = Cover the painted parts. = Remove screws @. ~ Remove cover @ with membrane. fresh brake fluid Bleed syringe (50323050000) (= p. 174) Brake fluid DOT 4/ DOT 5.1 (= p. 168) < = Draw the old brake fluid out of the brake fluid reservoir using a syringe and fil with [cooeso-12 = Mount bleeder cover @. Bleeder cover (00029013018) (= p. 172) ~ Connect the bleeding device. Bleeding device (00029013100) (= p. 172) = Open shut-off valve Info I Follow 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)14 BRAKE SYSTEM 15 Pall oft protection cap @ ofthe brake caliper bleeder screw. Connect the hose of the bleeder bottle. Bleeding device (00029013100) (= p. 172) Open bleeder screw @ by approx. one-half turn. © Info T Biced until fresh brake fluid emerges from the bleeder bottle hose without bubbles. Tighten the bleece screw Chose shutoff vane @. Open the bleeer screw again until brake Hud stops emerging Info T This prevents overiting ofthe brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro- tection cap. Disconnect the bleeding device. Remove the bleeder cover ‘Add brake fluid to level @, Guideline Distance @ (brake fluid level under | 5 mm (0.2 in) Upper edge of container) Brake fluid DOT 4/ DOT 5.1 (= p. 168) Position the cover with the membrane. Mount and tighten the screws. Info Tiean up overtiowed or spilt brake fluid immediately with water. ‘Check the hand brake lever for a firm pressure point. Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness @. Winimum tickness @ = Tamim @ 0.04 » If the minimum thickness is less than specified: = Change the front brake linings. (= p. 75) ‘Check the brake linings for damage and cracking. > If damage or cracking is visibie: = Change the front brake linings. (© p. 78) Warning Danger of accidents Incorrect maintenance will cause the brake system to fall = Ensure that service work and repairs are performed professionally.14 BRAKE SYSTEM 18 Warning Skin irtation Brake fluid causes skin lritation Keep brake fluid out of the reach of children, ‘Wear suitable protective clothing and satety glasses, o not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. If brake fluid spills on to your clothing, change the clothing. a) Warning TR aanert aces ld bat uit reduces te baking Make sure that brake fluid forthe front and rear brake is changed in accordance with the service schedule. YA Warning Aa are acidens io erase onthe take dies reduces the broking tet ‘Always keep the brake discs free of oil and grease. Clean the brake dises with brake cleaner when necessary, ogy Warning Av anger t accitens rae tnnes which have not been approved alter the raking eleney Not all brake linings are tested and approved for KTM motorcycles. The structure and fiction coefficient ofthe brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that dtfr from the original equipment, compliance withthe orginal homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the worranty shall be void. Only use brake linings approved and recommended by KTM. Warning Environmental hazard Hazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info Never use DOT 5 brake fluid! Its 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! = Move the brake fui reservoir mounted onthe handlebar toa horizontal positon. = Remove sces @ = Remove cover @ with membrane @. (@5 sx 1714) = Remove screws @. — Press back the brake linings with alight lateral iting of the brake caliper on the brake dise. Carefully pull the brake caliper backwards from the brake disc Press the brake piston back to its basic positon and make sure that no brake fluid overflows from the brake fluid reservoir. (95 sx 19716) = Remove screws @ and spacers. — Press back the brake linings with alight lateral iting of the brake caliper on the brake disc. Carefully pull the brake caliper backwards from the brake disc14 BRAKE SYSTEM n ~ Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. ~ Remove cotter pin © = Remove bolt @. = Take off retainer spring @ and remove the brake linings. = Clean the brake caliper. = Position the new brake linings © Info DH Atways change the brake linings in pair. = Position retainer spring @. = Mount bot @. Guideline Remaining screws, chassis Me 10.Nm (7.4 Ibtf) © Info TT make it easier to mount the pin, push the retainer spring down. Make sure the retainer spring is seated correctly, = Mount spring connector @. (85 sx 17714) ~ Position the brake caliper. Mount screws @ but do not tighten yet. — Operate the hand brake lever several times until the brake linings are Wying cor- rectly against the brake disc and there is @ pressure point. Fix the hand brake lever in the activated position, The brake caliper straigtens ~ Tranter screws @ Guideline Screw of brake caliper | MB Zann [Loc = (18.4 ot Fo = Remove the fation of the hand brake lever. (a5 sx 19/16) Poston the brake caliper. Mount screws @) wih the spacers but do nt tighten yet. — Operate the hand brake lever several times until the brake linings are lying cor- rectly against the brake disc and there is a pressure point. Fix the hand brake lever in the activated position. 7 The brake caliper straightens. ~ Tighten screws @. Guidetine Screw of brake caliper | MB 25 Nm Loctite® 243 (18.4 tor FO = Remove the fiation of the hand brake lever. = Add brake flid to level @. Guideline Level @ (brake fluid level below con- | 5 mm (0.2 in) tainer rim) Brake fluid DOT 4/ DOT 5.1 (™ p. 168) = Position the cover with the membrane. Mount and tighten the screws. Info T Wash off overtioned or spilled brake fluid immediately with water.14 BRAKE SYSTEM 78 Warning. Danger of accidents The brake system fails inthe event of overheating If there is no free travel on the foot brake lever, pressure builds up inthe brake system on the rear brake. Set the free travel on the foot brake lever in accordance with the specification. = Disconnect spring @. = Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guidetine Free travel at foot brake lever 3... 5mm (0.12... 0.2 in) » Ifthe free travel does not meet specitications: = Adjust the basic position of the foot brake lever. (© p. 78) toznesio} ~ Reconnect spring @ Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. ~ Set the free travel on the foot brake lever in accordance with the specification. = Detach spring @. ~ Loosen nut @ and, with push rod @, turn i back until you have maximum free travel = To adjust the basic position ofthe foot brake lever to individual requirements, loosen nut @ and turn serew @ occordialy. Info. TH The range of adjustment is limited. ~ Turn push rod @ accordingly until you have free travel @). Hf necessary, aqjust the basic position ofthe foot broke lever. Guideline Free travel at foot brake lever 3. 5mm 0.12... 02 in) = Hold screw @ and tighten nut @ Guideline ‘Nat, foot brake lever stop ue 20Nm (14.8 tof FO = Hold push rod @ and tighten nut @. Guideline Remaining nuts, chassis Me 10 Nm (7.4 Ibt FD) = Attach spring @.14 BRAKE SYSTEM 18 Warning Danger of accidents An insufficient brake fluid level wll cause the brake system to fall It the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings ae worn down, = Check the brake system and do not continue riding until the problem is eliminated Warning Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid fr the front and rear brake is changed in accordance with the service schedule, = Stand the vehicle upright. ~ Check the brake fluid level in viewer @. > Ifthe brake uid has dropped below marking @: = Add rear brake fluid. (5 p. 79) Warning Danger of accidents An insuficient brake fluid level will cause the brake system to fall If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake ln- ings are worn down, = Check the brake system and do not continue riding until the problem is eliminated, tation Brake fluid causes skin iritation ~ Keep brake fluid out of the reach of children. ~ Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact withthe skin, the eyes or clothing, = Consult @ doctor immediately if brake fluid has been swallowed. = Rinse the affected area with plenty of water inthe event of contact with the skin ~ Rinse eyes thoroughly with water immediately and consult a doctor it brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing, Warning Danger of accidents Old brake fluid reduces the braking effect. — Make sure that brake fluid fo the front and rear brake is changed in accordance withthe service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. = Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info Never use DOT 5 brake fluid. Itis silicone-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. Only use clean brake fluid from a sealed container. Preparatory work = Check the rear brake linings. (22 p. 81)14 BRAKE SYSTEM Main work = Stand the vehicle upright. ~ Remove serous @ ~ Toke of the cover withthe washer and membrane @. = Add brake fluid to level @. Brake fund DOT 47 DOT 5.1 p. TB) = Mount the cover with the washer and membrane. = Mount and tighten the screws. Info T Clean up overflowed or spilled brake fluid immediately with water. Warning Skin Brake fluid causes skin irritation = Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing, = Consult 2 doctor immediately if brake fluid has been swallowed, = Rinse the affected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing. Warning Environmental hazard) Hazardous substances cause environmental damage, = Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations, 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. 174) Brake fluid DOT 4 / DOT 5.1 (=p. 168)14 BRAKE SYSTEM 201964-10, Mount Bleeder cover @ Bleeder cover (OO02SOLSOIA) Tp. 7A) Connect the bleeding device. Bleeding device (00029013100) (= p. 172) Open shut-off valve Info I Follow 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 @. Guidetine Filling pressure 2... 2.5 bar (29... 36 psi) Pall off protection cap @ of he bleeder screw, Connect the hose of he bleeer boi Bleeding device (00029013100) ("= p. 172) Open bleeer screw @ by approx. one-half turn. into TH Bioed untit fresh brake fluid emerges from the bleeder bottle hose without bubbles. Tighten the bleeer screw, Close shutoff valve @ Open the blederstrew again unt rake fu stops emerging Info [This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the Hose of the Bleeder bottle. Mount the pro- tection cap. Disconnect the bleeding device, Remove the Bleeder cover, ‘dd brake fluid to tvel @. Brake faid DOT 47 DOT 5.1 p. 168) Position the membrane and the cover with the washer. Mount and tighten the screns. © Info Twas off vertioned or spilled brake fluid immediately with water. Check the foot brake lever for a firm pressure point. Warning Danger of accidents Worn-out brake linings reduce the braking effect. ~ Ensure that worn-out brake linings are replaced immediately.14 BRAKE SYSTEM 2 = check the brake linings fr minimum thickness @. 0 Winimum thickness @ EI mm @ 0.04 inp » If the minimum thickness is less than specified: = Change the rear brake linings. (= p. 82) = Check the brake linings for damage and cracking, > If damage or cracking is visible: = Change the rear brake linings. (© p. 82) 9 0008-10 Warning Danger of accidents Incorrect maintenance will cause the brake system to fail, Ensure that service work and repairs are performed professionally. Warning Brake fluid causes skin irtation — Keep brake fluid out of the reach of children. = Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing. = Consult 2 doctor immediately if brake fluid has been swallowed, = Rinse the affected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing. Warning Danger of accidents Old brake fluid reduces the braking effect. = Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. Always keep the brake discs free of oll and grease. = Clean the brake discs with brake cleaner when necessary. Warning I arr cies eine wich hart bon app arte bing tse Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, ‘and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void. = Only use brake linings approved and recommended by KTM. Mtrsing $F meme aoc subtree case enon amas Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info Never use DOT 5 brake fluid. Its 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. Only use clean brake fluid from a sealed container.14 BRAKE SYSTEM Stand the vehicle upright Remove screws @) Teke off the cover wth the washer and membrane @. Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if necessary, Toke off cotter pin @ and remove bolt Take of retaining spring @ and remove the brake linings. Clean the broke caliper. Position the new brake linings. Info TAtways change the brake linings in pairs. Position retaining sping @. Mount pin @. Guideline Rear brake bolt Me 12.Nm (8.9 IFT) ‘© Info To make it easier to mount the pin, push the retainer spring down. Make sure the retaining spring is seated correctly, Mount cote pins © Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is 2 pressure point. A brake fluid to evel @. Brake fuid DOT 47 OT 5.1 (sp, 168) Mount the cover with the washer and membrane @ Mount and tighten serens @. Info Clean up overflowed or spilled brake fluid immediately with water.