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KTM 450 EXC Racing Manual

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ENGLISH
35
MAINTENANCE WORK ON CHASSIS AND ENGINE »
General information about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series use a „floating“ mount. This means that the
brake calipers are not solidly attached to the caliper support, which enables
them to „float“ for maximum braking contact. Secure the screws of the caliper
support with Loctite 243 and tighten to 25 Nm.
BRAKE PADS:
The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front
and TOYO B 143 FF sintered lining at the back. These linings provide an opti-
mal 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.
FRONT: TOSHIBA H 38 (SINTERED) – harder to dose, good brake per-
formance, long life, for wet slippery terrain.
FERODO ID 450 (ORGANIC) – easy to dose, good brake per-
formance, short life, for dry terrain, low price
REAR: FERODO 4424 (organic) – better controllability, shorter service
life, for dry terrain.
TOSHIBA H38 (Sinter) – longer service life than FERODO 4424,
higher braking performance.
BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face [1] of the brake pads decreases. The brake disk must be at least
2.80 mm thick at the thinnest point [A]. Check the thickness of the brake
disk at several points.
– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,4 MM (0,016 IN)
CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI-
ATELY AS SOON AS THEY REACH THE WEAR LIMIT.
– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER
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 neces-
sary to top up the brake fluid. If the brake fluid level drops below the mini-
mum level either the brake system has a leak or the brake pads are completely
worn.In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,
one of the best brake 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 with DOT 5.1.
Never use brake fluid DOT 5. The color of this silicon oil-based product is
purple red. The gaskets and brake hoses of KTM motorcycles are not
designed for DOT 5 brake fluid.
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.
1
A
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