KTM ENDURO 640 LC4 - Manual (Page 27)

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MAINTENANCE WORK ON CHASSIS AND ENGINE
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General informations about KTM disc brakes
BRAKE CALIPERS (LC4 Enduro):
The brake calipers of this series “float“. This means that the brake calipers
are not solidly attached to the caliper support. Thus, the brake pads are always
in optimum contact with the brake disc. Secure the screws of the caliper sup-
port with Loctite 243 and tighten to 25 Nm.
BRAKE CALIPERS (LC4 Supermoto):
The front brake caliper [1] has 4 brake pistons and is rigidly connected to the
fork leg. The rear brake caliper has one brake piston and "floats", which means
that it is not rigidly connected to the brake caliper support. The resulting lat-
eral adjustment ensures that the brake pads [2] optimally rest against the
brake disk at any time. Secure the screws [3] of the caliper support with Loctite
243 and tighten to 40 Nm.
BRAKE PADS (LC4 Enduro):
The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front
and ID450 organic lining at the back.
BRAKE PADS (LC4 Supermoto):
The brake pads are fitted with ID450 organic lining
These linings provide an optimal combination of dosing, brake performance
and life cycle. The lining type is stated on the back of the brake pad and also
recorded in the homologation papers.
Other brake pads are available for competition sports.
BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR-
IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE
PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN
DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER-
ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT
CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF-
FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS
AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY
WILL BE VOID.
BRAKE FLUID:
KTM fills the brake systems with „Motorex Brake Fluid DOT 5.1“ brake fluid,
one of the best brake fluids that is currently available. We recommend that
you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an
amber color. If you do not have any DOT 5.1 for refilling, you may use DOT
4 brake fluid. However, you should replace it as soon as possible by DOT 5.1.
Never use DOT 5 braking fluid. It is based on silicone oil and has a purple
color. Gaskets and brake hoses are not compatible with it.
HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR
MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE-
QUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCK-
ETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING
THE BRAKE SYSTEM TO FAIL.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not
necessary to top up the brake fluid. If the brake fluid level drops below the
minimum either the brake system has a leak or the brake pads are
completely worn down. In this case, consult an authorized KTM dealer imme-
diately.
BRAKE DISCS:
Wear reduces the thickness of the brake disc in the area of contact [4] with
the brake pads. At its thinnest spot [A], the brake disc must not be more than
0.4mm thinner than its nominal dimension [B]. The nominal dimension can
be gaged in a location beyond the area of contact with the brake pads. Check
wear in several spots.
– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM CONSTITUTE
A SAFETY HAZARD. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON
AS IT REACHES ITS WEAR LIMIT.
– AS A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CAR-
RIED OUT BY A LICENSED KTM MECHANIC.
LC4 Enduro
LC4 Supermoto
1
2
3
A
B
4