KTM 250 EXC 2004 - Manual (Page 33)

ENGLISH
32
Adjusting the free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjustment
screw
1 . In this way, the position of the point of pressure (i.e. the resis-
tance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.
When you press the hand brake lever forwards, you should have at least
3 mm free travel. Turn the adjusting screw
1 if necessary.
! CAUTION !
A T THE HAND BRAKE LEVER , FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN ). O NLY
THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED ( TO BE RECOGNIZED BY
THE GREATER RESISTANCE OF THE HAND BRAKE LEVER ). I F THIS FREE TRAVEL IS NOT PRO -
VIDED , PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM , AND THE FRONT - WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING .
Checking the brake fluid level - front brake
The brake fluid reservoir is linked with the hand brake cylinder at the
handlebar and the reservoir is provided with an inspection glass. With the
reservoir in a horizontal position, the brake fluid level should not drop below
the middle of the glass.
ƽ WARNING ƽ
I F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN . I N THIS CASE , CONSULT AN
AUTHORIZED KTM DEALER IMMEDIATELY .
Refilling the front brake fluid reservoir *
Loosen screws 2 and remove lid 3 and membrane 4 .
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1
(e.g. Motorex Brake Fluid DOT 5.1). Replace membrane and lid, tighten
screws. Rinse off spilled or overflowing brake fluid with water.
ƽ WARNING ƽ
– N EVER USE DOT5 BRAKE FLUID ! I T IS BASED ON SILICONE OIL AND OF A PURPLE
COLOR . S EALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT .
– S TORE BRAKE FLUID OUT OF REACH OF CHILDREN .
– B RAKE FLUID CAN CAUSE SKIN IRRITATION . A VOID CONTACT WITH SKIN AND EYES . I F
YOU GET BRAKE FLUID IN YOUR EYES , RINSE WITH PLENTY OF WATER AND CONSULT A
DOCTOR
! CAUTION !
– D ON ’ T LET BRAKE FLUID GET IN CONTACT WITH PAINT , IT IS AN EFFECTIVE PAINT REMOVER .
– U SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER .
Checking the front brake pads
The brake pads can be inspected from below. The linings must be at least
1 mm (0.04 in) thick.
ƽ WARNING ƽ
A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM ,
OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFETY DON ’ T PUT
OFF HAVING YOUR BRAKE PADS CHANGED .
! CAUTION !
I F 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
5 mm
2
3
4
1
min. 3 mm