Antilock braking system (ABS)
ABS unit 1, which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the fuel tank. One wheel speed sensor 2 is located in each case on the front and the rear wheel.
Warning
Danger of accidents Changes to the vehicle impair the function of the ABS.
- Only allow the rear wheel to spin with the front brake applied away from public road traffic if the ABS is switched off.
- Do not make any changes to the suspension travel.
- Only use spare parts on the brake system which have been approved and recommended by KTM.
- Only use tires/wheels approved by KTM with the corresponding speed index.
- Maintain the specified tire air pressure.
- Service work and repairs must be performed professionally.(Your authorized KTM workshop will be glad to help.)
Warning
Voiding of the government approval for road use and the insurance coverage
- If the ABS is switched off completely, the vehicle's approval for road use is invalidated.
– Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely.
The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
Warning
Danger of accidents Driving aids can only prevent a rollover within the physical limitations.
It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.
– Adapt your riding style to the road conditions and your driving ability.
The ABS operates with two independent brake circuits (front and rear brakes). During nor- mal operation, the brake system operates like a conventional brake system without ABS. When the ABS control unit detects a locking tendency in a wheel, ABS begins regulating the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.
The ABS indicator lamp 3 must light up after the ignition is switched on and go out after starting off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays functional; only ABS control is not available.
The ABS indicator lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions, for example when making "wheelies" or if the rear wheel spins. This causes the ABS to switch off.
To reactivate the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reactivated when the vehicle is switched on again. The ABS indicator lamp goes out when you start off.
- Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel 1.
Info
Push the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding.
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
– Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness A.
Info
Wear will reduce the thickness of the brake disc at contact surface 1 of the brake linings.
| Brake discs - wear limit | |
| Front | 4.5 mm |
| Rear | 3.6 mm |
- Change the front brake disc.
- Change the rear brake disc.
Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
- Change the front brake disc.
- Change the rear brake disc.
Checking the brake fluid level of the front brake
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
- Check the brake fluid level in viewer 1.
» If the brake fluid is below the MIN marking.
Adding front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Warning
Skin Irritation Brake fluid causes skin irritation
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
- Check the front brake linings.
Main work
- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws 1
- Remove cover 1 with membrane 2.
- Add brake fluid to level A.
| Level A | 5 mm |
| Brake fluid DOT 4 / DOT 5.1 | |
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
- Check the brake linings for minimum thickness A.
| Minimum thickness A | ≥ 1 mm |
- Change the front brake linings.
- Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the front brake linings.
Checking the free travel of foot brake lever
Warning
Danger of accidents
The brake system fails in the event of overheating.If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
- Disconnect spring 1.
- 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 A.
Guideline
| Free travel at foot brake lever | ≥ 3… 5 mm |
– Adjust the free travel of the foot brake lever.
- Reconnect spring 1.
Adjusting the free travel of the foot brake lever
Warning
Danger of accidents
The brake system fails in the event of overheating.If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
- Detach spring 1.
- Release nut 2 and use screw 3 to adjust the specified free travel A.
Guideline
| Free travel at foot brake lever | ≥ 3… 5 mm |
– Attach spring 1.
Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
- Stand the vehicle upright.
- Check the brake fluid level of the brake fluid reservoir.
» If the fluid level reaches the MIN marking 1:
- Add rear brake fluid.
Adding the rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Check the brake linings of the rear brake.
Main work
Condition
The screw cap is locked.
- Remove screw 1 and take off the screw cap lock
- Stand the vehicle upright.
- Remove screw cap 2 with membrane 3
- Add brake fluid to level A.
| Brake fluid DOT 4 / DOT 5.1 |
Info
Clean up overflowed or spilt brake fluid immediately with water.
Condition
The screw cap is locked
- Position the screw cap lock and mount and tighten screw 1.
Guideline
| Screw, compensating tank cap lock, rear brake | M5 | 9 Nm |
Checking the brake linings of the rear brake
Warning Danger of accidents Worn-out brake linings reduce the braking effect. - Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.
- Check the brake linings for minimum thickness A.
| Minimum thickness A | ≥ 1 mm |
– Change the rear brake linings.
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
– Change the rear brake linings.
