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KTM 150 SX - Checking the Free Travel of Foot Brake Lever; Adjusting the Basic Position of the Foot Brake Lever

KTM 150 SX
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12 BRAKE SYSTEM 79
L00956-11
Correct the brake fluid quantity to level
.
Guideline
Dimension
(brake fluid level below
top edge of container)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 134)
Position the cover with the membrane. Mount and tighten the screws.
Info
Wash off overflowed or spilled brake fluid immediately with water.
12.8 Checking the free travel of foot brake lever
Warning
Danger of accidentsBrake system failure.
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
402026-10
Disconnect spring
.
Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel
.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
Adjust the basic position of the foot brake lever. ( p. 79)
Reconnect spring
.
12.9 Adjusting the basic position of the foot brake lever
Warning
Danger of accidentsBrake system failure.
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.
C00923-10
(All 125/150 models)
Disconnect spring
.
Loosen nut
and, with push rod
, turn it back until you have maximum
free travel.
To adjust the basic position of the foot brake lever to individual requirements,
loosen nut
and turn screw
accordingly.
Info
The range of adjustment is limited.
Turn push rod
accordingly until you have free travel
. If necessary,
adjust the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
Hold screw
and tighten nut
.
Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 lbf ft)
Hold push rod
and tighten nut
.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)

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