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KTM 500 EXC - Page 71

KTM 500 EXC
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12 BRAKE SYSTEM 69
101374-11
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws 1.
Remove cover 2 with membrane 3.
Manually press the brake caliper toward the brake disc to push back the brake pis-
tons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract-
ing it by suction if it does.
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
101376-10
Remove cotter pin 4, pull out pin 5, and remove the brake linings.
Clean the brake caliper and brake caliper support.
100397-01
Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake
caliper support are seated correctly.
100398-10
Insert the brake linings, insert the pin, and mount the cotter pin.
Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
101374-12
Correct the brake fluid quantity to level A.
Guideline
Dimension A (brake fluid level below
top edge of container)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 109)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.

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