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ENGLISH

12

General information about KTM disc brakes

BRAKE FLUID RESERVOIR:
The brake fluid reservoir on front wheel brake has been designed in such a
way that even if the brake pads are worn it is not necessary to top up the
brake fluid. If the brake fluid level drops below the minimum 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 system with ”Shell Advance Brake DOT 5.1”, one of the
best brake fluids 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 by DOT 5.1.

Adjusting of free travel at the hand brake lever

Free travel at the hand brake lever may be readjusted by using adjustment
screw 

2

. In this way, the position of the point of pressure (i.e., the resi-

stance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.
For this purpose, undo the counter nut 

1

and twist the adjustment screw

2

until he desired adjustment is achieved. After the adjustment process

retighten the counter nut.

!

CAUTION

!

A

T THE HAND BRAKE LEVER

FREE TRAVEL MUST AT LEAST BE

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 PROVI

-

DED

PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM

AND THE FRONT

-

WHEEL BRAKE

MAY FAIL DUE TO OVERHEATING

.

Checking of brake fluid level - front brake

The brake fluid reservoir is combined with the hand brake cylinder on the
handlebar and provided with an inspection glass. When the brake fluid
reservoir is in a horizontal position, the brake fluid level should not drop
below the "MIN" mark on the inspection glass.

WARNING

D

ROPPING OF THE BRAKE FLUID LEVEL BELOW THE

"MIN" 

MARK INDICATES LEAKS IN

THE BRAKE SYSTEM OR TOTALLY WORN BRAKE PADS

. I

N THIS CASE

IMMEDIATELY

CONTACT A LICENSED

KTM 

DEALER

.

Refilling the front brake fluid reservoir *

When the brake fluid falls to the middle of the inspection glass, new brake
fluid has to be added.
Loosen screws 

3

and remove lid 

4

and membrane 

5

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
(Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.

WARNING

– N

EVER USE

DOT 5 

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

.

5 mm

1

2

min. 3 mm

3

4

5

Содержание 60 SX 1999

Страница 1: ...S H H H HA A A AN N N ND D D DB B B BO O O OO O O OK K K K M M M MA A A AN N N NU U U UE E E EL L L L D D D D U U U UT T T TI I I IL L L LI I I IS S S SA A A AT T T TI I I IO O O ON N N N M M M MA A...

Страница 2: ......

Страница 3: ...COMMENDATIONS THAT WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE MOTORCYCLE PROPERLY IN THE INTEREST OF EVERYBODY INVOLVED WE URGE YOU TO PAY PARTI CULAR ATTENTION TO INSTRUCTIONS AND INF...

Страница 4: ...s depends on the efforts made by the parents to ensure that the motorcycle is kept in good working order and only used on safe terrains Nevertheless driving the motorcycle like driving any other vehic...

Страница 5: ...about KTM disc brakes 12 Adjusting of free travel at the hand brake lever 12 Checking of brake fluid level front brake 12 Refilling the front brake fluid reservoir 12 Checking the front brake pads 13...

Страница 6: ...he speed should be adjusted to your youngster and not the other way around Your youngster must understand that all instructions he or she receives from you or any other supervising adult must be follo...

Страница 7: ...0 mm 0 4 in at this lever measured at outer edge CAUTION IF THERE IS NO PLAY ON THE CLUTCH LEVER THE CLUTCH WILL START TO SLIP THE CLUTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS Hand brake le...

Страница 8: ...EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY CAUTION ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED W...

Страница 9: ...HEN KICKING NOT VEHEMENTLY ENOUGH Rebound damping function of the shock absorber The damping effect of the rebound damping mechanism can be adjusted to 14 different levels by means of the setting whee...

Страница 10: ...uld check before each start When you start off the motorcycle must be in a perfect technbical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle bef...

Страница 11: ...HIGH SPEED WILL REDUCE THE LIFE OF THE ENGINE WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL LOAD NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANG...

Страница 12: ...r Check thickness of disc brake pads front Check brake drum and brake disc Check freeplay and operation of hand brake lever and foot brake lever Inspect condition and installation of brake hose Check...

Страница 13: ...D CAN GET OUT OF CONTROL CAUTION THE HANDLEBAR MUST MOVE EASILY OTHERWISE THE BEARINGS WILL BE DAMAGED IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUEN...

Страница 14: ...GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVI DED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking of brake fl...

Страница 15: ...he brake caliper Then remo ve the brake pads by pulling them downwards Before installing the new brake pads push the brake pistons backwards with an appropriate screwdriver Insert the brake pads into...

Страница 16: ...e brake shoes Before mounting new brake shoes check the brake cam 2 for smooth ope ration and apply a thin coat of copper paste to the contact surfaces for the brake shoes Slightly roughen the new bra...

Страница 17: ...RAKING EFFECTS WOULD BE STRONGLY REDUCED Removing and installing the rear wheel Jack the motorcycle up by the frame Remove the hexagon nut 3 of the wheel spindle together with the was her 4 and remove...

Страница 18: ...e counter nuts 2 Before tightening the two hexagon nuts 1 make sure that the chain adjuster 4 is properly resting against the tensioning screws 3 and that the rear wheel is properly aligned with the f...

Страница 19: ...l to become unba lanced and before long other spokes will have come loose Check spoke ten sion especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a sc...

Страница 20: ...ure they are centered B and lock into place with the filter holder 1 Adjusting the clutch cable When the engine is cold the play of the clutch lever should be 10 mm mea sure play at the outer end of t...

Страница 21: ...be possible to achieve a reliable result If necessary add engine oil 10W40 e g Shell Advance Ultra 4 CAUTION NOT ENOUGH OIL OR A POOR OIL QUALITY LEAD TO PREMATURE WEAR OF THE TRANS MISSION THEREFORE...

Страница 22: ...HE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Exhaust system The main silencer is filled with glass fiber yarn Heat however causes the glass fiber yarn filling to disintegrate which can reduce the overal...

Страница 23: ...wear may cause carbu retor malfunction e g overly rich mixture Therefore these parts should be replaced after 1000 hours of using Idling range A Operation with closed throttle valve This range is infl...

Страница 24: ...ystem you should treat the short circuit button with a contact spray If you want to put your motorcycle away for longer periods of time please observe the following instructions Clean motorcycle thoro...

Страница 25: ...dy height max 160 cm 63 in Rider s body weight max 50 kg 110 lbs Recommended age of rider 8 to 12 years Engine CR 60 CR63 TECHNICAL SPECIFICATIONS CHASSIS 60 SX 65 SX 99 Hexagon screw brake caliper M...

Страница 26: ...e ball bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston rings 1 compression ring Primary drive straight cut spur gears 23 75 t Transmission 6 speed claw actuated...

Страница 27: ...ng end gap max 0 15 mm 0 00590 in Clutch springs length min 27 mm 1 06 in Transmission shafts end float 0 10 0 20 mm 0 00394 0 00787 in TOLERANCES AND FITTING CLEARANCES Hexagon nut primary gear M 10...

Страница 28: ...T M S P O R T M O T O R C Y C L E A G A 5 2 3 0 M a t t i g h o f e n P o s t f a c h 9 1 A u s t r i a I n t e r n e t h t t p w w w k t m c o a t FN 102019 d Landesgericht Ried im Innkreis 3 205 59...

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