Question about 2004 KTM EXC 450 Racing

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The brakes on my KTM 450 EXC 2004 MODEL ARE NOT WORKING. THE BIKE HAS NOT BEEN RIDDEN FOR SOME TIME. THERE IS NO BACK PRESSURE WHEN I PUT THE BRAKES ON.

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  • sean_boman Sep 29, 2009

    I ASSUMED THAT THEY MIGHT NEED bleeding but am not sure how to do it and I dont have a manual with me.

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Are the brakes operated hydraulically, which it should be since front & rear have disc brakes, then check the level of brake fluid in the Master cylinder. As you have'nt ridden it for some time there exists a probability of air entering the pipeline causing an air-lock such that you will hardly get any back pressure when applying the brake. If there is sufficient quantity of brake fluid present, then try bleeding it at the wheel till all air is removed.The disk brake operates by pushing the brake pads on the disk simultaneously, so check if the brakes are moving in when applying any brake. The that small piston expander at the wheel end may be damaged by rust or a particle obstructing the piston assembly. Also when bleeding it, pump the brakes vigorously............sodeep

Posted on Sep 29, 2009

  • Sudeep Chatterjee
    Sudeep Chatterjee Sep 29, 2009

    The point the brake pipeline is attached to(at the place where the brake pipe is joined to the brake assembly) is threaded. Loosen it slightly(1/2 turn) and pump the appropriate brake. Do it one wheel at a time & ensure no more brake fluid along with bubbles of air is bled. Tighten the joint & ask someone to pump that brake while you tighten the line.....................................sodeep

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Theres really not much to them and only a few things could be the case. Try bleeding the brake system first and check for leaks. Also make sure the fluid is changed. If that doesn't give pressure the master cylinder has gone bad and needs to be replaced..

Posted on Sep 29, 2009

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Thank you for contacting FixYa with your inquiry.
The Rubber Diaphragm by nature is usually somewhat collapsed and twisted looking. Unless it appears to be non functional it's probably OK. It's important to have fluid and make sure the air is out of the system. There is a bleeder screw to allow for evacuating the air out of the system.
http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx Go To: 2004 > 450 EXC-G RACING (USA) > CHASSIS > BRAKE CALIPER REAR
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You can purchase Service/Repair Manuals from this site: http://www.repairmanual.com/KTM.html
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