KTM 85SX - Manual (Page 24)

ENGLISH
23
MAINTENANCE WORK ON CHASSIS AND ENGINE
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Changing basic position of the brake pedal *
The basic setting of the foot brake pedal can be changed by turning the end
stop roller [1]. Using the push rod [2], the free play on the foot brake pedal
must be set.
Measured on the outside, the foot brake pedal must have 3-5 mm of free play
before the push rod can move the piston in the brake cylinder (to be recog-
nised from the resistance on the foot brake pedal).
IF THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYS-
TEM AND THE BRAKE PADS BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS
AND CAN FAIL COMPLETELY IN EXTREME CASES.
Checking the rear brake fluid level
The reservoir for the rear disk brake is on the right side of the motorcycle on
the rear brake cylinder.
The brake fluid level may not drop below the upper edge A of the inspection
glass when the bike is in a horizontal position.
IF THE BRAKE FLUID LEVEL DROPS BELOW THE UPPER EDGE OF THE INSPEC-
TION GLASS, THIS INDICATES THAT THE BRAKE SYSTEM IS EITHER LEAKING OR
THE BRAKE SHOES COMPLETELY WORN.
Checking rear brake pads
The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).
AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER
THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN
SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY
OR ENTIRELY WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB
AGAINST THE BRAKE DISC, THEREBY IMPARING THE BRAKING EFFECT AND
DESTROYING THE BRAKE DISC.
min.
1 mm
A
Refilling the rear brake fluid reservoir *
Remove the screws [3] and take off the cover [4] and diaphragm [5].The brake
pistons must be pushed back to their basic position. Fill DOT 5.1 brake fluid
(e.g. Motorex Brake Fluid DOT 5.1) up to 8 mm under the upper edge of the
reservoir.
Remount the diaphragm, cover and screws and actuate the foot brake lever
until you feel the point of pressure again. Wipe any overflowing or spilled brake
fluid off with water.
– ACTUATE THE FOOT BRAKE LEVER UNTIL YOU FEEL THE POINT OF PRESSURE
AGAIN.
– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A
PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED
TO IT.
– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND
EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER
AND CONSULT A DOCTOR.
– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE
PAINT REMOVER.
– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
3
4
5
3-5mm 1
2