12 BRAKE SYSTEM 53
12.1 Checking the free travel of the hand brake lever
Warning
Danger of accidents Brake system failure.
– 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.
C00474-10
– Push the hand brake lever forward and check free travel A.
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the handbrake lever. ( p. 53)
12.2 Adjusting the free travel of the handbrake lever
C00475-10
– Check the free travel of the hand brake lever. ( p. 53)
– Adjust the free travel of the handbrake lever with adjustment screw 1.
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply force.
Do not make any adjustments while riding!
12.3 Checking the brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
400257-10
– Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement A.
Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the brake disc.
– Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc shows signs of damage, cracking, or deformation:
– Change the brake disc.
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