Question about 2004 KTM SX 125

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How do Iremove the rear foot brake piston on ktm 85? I am replacing the whole kit and am trying to remove the piston from the brake cylinder.

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A compressed air hose will do it, just make sure it is wrapped in rags to catch the piston and some brake fluid that will come out.
Dont point it towards anyone when you do it.

Posted on Jul 17, 2010

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1 Answer

1982 Gold Wing Aspend brake pedal is frozen


If the lever is frozen in the pivot shaft, use a penetrating oil to loosen the pedal and remove it. Clean the rust off grease the shaft and put the lever back on. If the piston is frozen in the master cylinder of the rear brake, then get a piston kit from the local Honda dealer, remover the master cylinder assembly from the cycle clean rebuild and reinstall, then bleed the system. Consider removing the brake caliper and clean the corrosion out of the piston seal groove. This will keep you from having future problems. You will need to get the master cylinder working to get the piston out USING BRAKE FLUID PRESSURE so you do not damage the piston in the caliper when you go to clean the seal grooves.

Sep 25, 2011 | 1982 Honda GL 1100 Gold Wing

1 Answer

Could you tell me what the torque specs would be to tighten the cylinder head on a KTM 85?


Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to ensure your issue has been resolved.

KTM Torque settings


  1. Collar screw, front wheel spindle Front axle nut 40Nm 30ft lbs
  2. Brake Caliper front Brake Caliper front Loctite 243 2 19ft lbs
  3. Brake Disk, front Brake disk front Loctite 243 1 11ft lbs
  4. Brake Disk, rear Brake disk rear Loctite 243 1 11ft lbs
  5. Clamping screws, upper fork bridge Top triple clamp 20Nm 15ft lbs
  6. Clamping screws, lower fork bridge Bottom triple clamp 15Nm 11ft lbs
  7. Clamping screws, fork stubs Front axle pinch bolts 10Nm 7ft lbs
  8. Collar nut, rear wheel spindle Rear axle nut 80Nm 59ft lbs
  9. Hex nut swingarm bolt Swingarm nut 100Nm 74ft lbs
  10. Hex collar screw handlebar clamp Upper handlebar clamps 20Nm 15ft lbs
  11. Allen head screw handlebar support Lower handlebar clamps Loctite 243 4 30ft lbs
  12. Shock absorber top Shock absorber top bolt 60Nm 44ft lbs
  13. Shock absorber bottom Shock absorber botton bolt 60Nm 44ft lbs
  14. Sprocket screws Rear sprocket bolts Loctite 243 3 25ft lbs
  15. Ball joint for push rod Rear brake pedal pivot Loctite 243 1 7ft lbs
  16. Engine mounting bolts Engine mounting bolts 45Nm 33ft lbs
  17. Engine brace Engine brace 33Nm 24ft lbs
  18. Screw adjusting ring spring preload Shock preload collar bolt 8Nm 6ft lbs
  19. Spoke nipple Spokes 5Nm 4ft lbs
  20. Other Screws on chassis M6 10Nm 7ft lbs
  21. M8 25Nm 19ft lbs
  22. M10 45Nm 33ft lbs
  23. Other collar nutes on chassis M6 15Nm 11ft lbs
  24. M8 30Nm 22ft lbs
  25. M10 50Nm 37ft lbs
  26. Front Sprocket 44ft lbs

TF

Sep 03, 2011 | KTM Pag Spyder 300 Motorcycles

2 Answers

I have a BMW 520i 1992 car .. and here is the problem : it happens when I push the brake pedal .. I feel like something is knocking under my foot .. and sometimes the rear wheels brakes catch unexpectly...


Hi, what you feel is your anti-lock brake actuator pumping the brakes. This is probably due to dirty/dusty or improperly adjusted brake shoes causing the rear brakes to lock. It is also possible that you have a leak in one or both rear brake cylinders. Have your rear brakes checked, cleaned, and adjusted. If you would like to do it yourself, I can provide instructions--just let me know.

Aug 13, 2011 | 1992 BMW 5 Series

1 Answer

My rear brake dose not work. When I removed the cap on my rear master cylinder the rubber plunger or diaphram was twisted and colapsed. Would this mean it is bad. Cant race with no rear brakes help. Its a...


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
Also look at the repair kit Item #2 (50313081200)
You can purchase a complete repair manual from this site: http://store.payloadz.com/details/391226-eBooks-Technical-2003-2004-KTM-450-525-EXC-Racing-Owners-Manual.html
Make sure you have serviceable pads, proper KTM brake fluid, and the air is out of the system and the brake cylinder is functional and you will have brakes. There is also an accessory available the cools the fluid for the rear brakes and keeps them from fading if you ride the pedal or are constantly braking. Ask you dealer.
Let us know if we can be of further service.

Kind regards,
TF

Jul 17, 2011 | 2004 KTM EXC 450 Racing

1 Answer

How do i replace rear brake pads off a 1995 ford contour


Check this REMOVAL & INSTALLATION
(see Figures 1, 2 and 3 / click over images for zoom )

CAUTION Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
  1. Remove 1 / 2 of the brake fluid from the master cylinder reservoir.
  2. Raise and safely support the vehicle.
  3. Remove the wheels.
  4. Remove the cotter pin and guide pin.
zjlimited_1153.jpg

Fig. 1: Rear disc brake components

  1. Remove the caliper locating pin cover and remove the locating pin.
  2. Swing the rear disc brake caliper away from the brake rotor and anchor plate. There is no need to remove the parking brake cable or brake hose.
  3. Remove the inner and outer disc brake pads.
To install:
  1. If installing new disc brake pads, use rear caliper piston adjuster T87P-2588-A or similar tool, to rotate the rear disc brake piston clockwise, retracting the caliper piston. This will allow room for the new brake pads.
zjlimited_1154.jpg

Fig. 2: Removing the parking brake cable

zjlimited_1155.jpg

Fig. 3: Use the adjuster tool to rotate the piston into the caliper

  1. Install the inner and outer disc brake pads.
  2. Swing the rear disc brake caliper back into position over the disc brake pads.
  3. Clean the locating pin threads and apply 1 drop of a thread locking agent or similar sealer.
  4. Apply a small amount of disc brake caliper slide grease to the shaft of the locating pin.
  5. Reinstall the locating pin and torque to 30 ft. lbs. (41 Nm).
  6. Reinstall the guide pin and the cotter pin.
  7. Adjust the parking brake by operating the parking brake control several times.
  8. Reinstall the wheel and tire assembly. Torque the lug nuts to 62 ft. lbs. (85 Nm).
  9. Lower the vehicle.
  10. Adjust the parking brake by operating the parking brake control several times.
  11. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle.
  12. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary.
  13. Road test the vehicle and check for proper brake system operation.

Hope this helps (remember to rate and comment this answer).

May 01, 2011 | 1995 Ford Contour

2 Answers

I should have said what kind of leak I have brake fluid leaking from the rear passinger tire


you mean from "near" your rear passenger tire. Tires don't have brake fluid in them...!
Take a look at the inner part where the wheel mounts to the axle. There is a brake line there, so look to see if it looks like the brake fluid is coming from it, (and that you verify the brake fluid resevoir under the hood is low) or that it might be from the brake drum area. If it's from the brake drum, you probably have a "wheel cylinder" leaking, and need to remove the wheel and drum to verify this.

Nov 12, 2010 | 1992 Chevrolet S-10 Blazer

1 Answer

I need a price for Front forks


You might be best servered by taking your list to your local HD dealer, or calling say a Dennis Kirk, ot J&P Cycles. As they can give you best prices on the package for the parts you need.

Oct 06, 2009 | 2001 Harley Davidson FXST Softail Standard

1 Answer

Rear brake cylinder and bleeding


Relax....KTM's are delicate in this procedure.
First of all make sure that you are using DOT 5.1 brake fluid and not 4 as we use in the Japan models.
Then take the rear caliper in your hands and push the piston all the way in.Then bolt it on its position.
Bolt on the brake hose to the rear caliper tight and leave it loose on the rear master cylinder side (loose but ready to tight it on like half circle loose) and clean up the reservoir completely.
Take a syringe from a pharmacy and a piece of 3mm clear tube.
Start pushing brake fluid in the caliper's loose bleeder until you see fluid coming out fron the hose's loose end on the master cylinder.
The tight the cylinder's bolt and keep pushing fluid until you see it filling up the reservoir.
When you see the reservoir fully filled up, tight the bleeder, take out the syringe and start pressing the brake pedal 15-20 times and the last one keep it down and loose the bleeder (with a tube attached to it and to a bottle) for a sec to relieve the pressure along with any air bubbles.DON'T LIFT THE PEDAL UNTIL YOU HAVE TIGHT BACK THE BLEEDER or the system will **** air in.FIRST tight the bleeder and THEN loose the pedal.
Keep doing that until NO air comes out of the system.
While you are doing this second stage keep filling up the reservoir and do not let the master cylinder **** air in.

Jun 15, 2009 | 2002 KTM LC8 950 Rally

1 Answer

How to change back brakes? I can't get the brake cylinder to go in.


Do you mean back brake pads or the back brake callipers?
To change pads you need to use a rear brake pads changing tool to screw in the calliper piston or if you are experienced enough you could screw in the calliper with a two mm thick piece of metal sheeting that fits into the grove of the piston.
If you need to replace the whole calliper remove the hand brake cable first and clamp the flexible brake hose remove brake hose, remove the callier with cylinder and then remove the calliper holder. fit new holder pads and locks and the calliper with the piston and the brake hose and the hand brake cable. Bleed the brakes. Mike

Apr 26, 2009 | 2001 Volkswagen Beetle

2 Answers

I need to set the brakes on my vw beetle. I pump up to 3 or 4 times before my brakes take. Please assist me


Sounds like air in the hydraulic system.

On each brake cylinder there is a bleed screw with a pipe nipple on it. Buy fresh brake fluid for the specification of the vehicle (Dot3 or Dot4), and an EasyBleed kit. Attatch easybleed pipe to each bleed nipple in turn, and slacken it off 1/2 a turn. -put the other end in a large jam jar.
Once you have undone one bleed nipple, top up brake reservoir to maximum, and pump foot pedal twice - re top up and repeat.
Tighten up bleed nipple, and move on to another untill complete.

If this does not solve the problem, check the rear brakes for automatic adjusters. Sometimes they sieze- or bend.
If defective - reoplace as a kit on both sides. Do not just replace one. All brake work should be completed as axle pairs.

Hope this helps.

Jun 13, 2008 | 1998 Volkswagen Beetle

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