KTM 6351390204401A BRAKE Lever Instructions
- June 9, 2024
- KTM
Table of Contents
FITTING
INSTRUCTIONS
BRAKE LEVER
6351390204401A
63513902044
MEANS OF REPRESENTATION
1.1 Symbols used
The meaning of specific symbols is described below.
| Indicates an expected reaction (e.g., of a work step or a function).
---|---
| Indicates an unexpected reaction (e.g., of a work step or a function).
| All work marked with this symbol requires specialist knowledge and technical
understanding.
In the interest of your own safety, have these jobs performed by an authorized
workshop. Your motorcycle will be cared for there to the highest degree by
specially trained experts using the special tools required.
| Indicates a page reference (more information is provided on the specified
page).
| Indicates information with more details or tips.
| Indicates the result of a testing step.
| Indicates a voltage measurement.
| Indicates a current measurement.
| Indicates the end of an activity, including potential reworking.
1.2 Formats used
The typographical formats used in this document are explained below.
| Proprietary name | Indicates a proprietary name. |
|---|---|
| Name® | Indicates a protected name. |
| Brand™ | Indicates a brand available on the open market. |
| Underlined terms | Refer to technical details of the vehicle or indicate |
technical terms, which are explained in the glossary.
2.1 Use definition – intended use
It is imperative that an authorized dealer provide expert consultation on
technical accessories and install them properly using a special tool to ensure
optimum safety and functioning. Homologation documents are available for
articles with markings (EC, ECE, etc.,). The customer must check, if if
necessary with the national approving authorities, if these homologation
documents ensure total homologation of the respective vehicle with installed
technical accessories in the planned country of usage. If you have any further
questions, contact your authorized dealer.
Info
EU markings: EC (EC type approval), ECE (ECE type approval), ABE (national
type approval (NTA)), EC‑ V (EC type approval for motor vehicles), FIM (FIM
noise conformity), CCCUO_EU (not permitted for use on public roads) and HONN
(homologation not necessary)
USA markings: 50 states (50 states law), USFS (US Forest Service), FIM (FIM
noise conformity), AMA (‑ amateur noise conformity), DOT (Department of
Transportation) and CCCUO (not permitted for use on public roads)
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as
intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not
meet the required specification for the respective use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the product
described safely. Therefore read this instruction and all further instructions
included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on
the product described. Do not remove any information or warning labels. If
they are missing, you or others may not recognize dangers and may therefore be
injured.
2.4 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or
serious permanent injury if the appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the
appropriate measures are not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate
measures are not taken.
2.5 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or
herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs
or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in
unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an
enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is
operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock
absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in
accordance with its intended use, and in a safe and environmentally compatible
manner.
The vehicle should only be used by trained persons. An appropriate driver’s
license is needed to drive the vehicle on public roads.
Have any faults that impair safety immediately remedied by an authorized
workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased
safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well
as trousers and a jacket with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the
legal regulations.
In the interest of your own safety, KTM AG recommends that you only operate the vehicle while wearing suitable protective clothing.
2.7 Work rules
Unless specified otherwise, the ignition must be turned off during all work
(models with ignition lock, models with remote key) or the engine must be at a
standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component
of the vehicle, but can be ordered using the number in parentheses. Example:
bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
| Ambient temperature | 20 °C (68 °F) |
|---|---|
| Ambient air pressure | 1,013 mbar (14.69 psi) |
| Relative air humidity | 60 ± 5 % |
During assembly, use new parts to replace parts which cannot be reused (e.g.
self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings,
pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required.
Observe the manufacturer’s instructi- ons.
If thread locker (e.g., Precote®) has already been applied to a new part, do
not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for
damage and wear. Change damaged or worn parts.
After completing a repair or service work, check the operating safety of the
vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and
conflicts do not occur. To protect the future of the motorcycle sport, make
sure that you use your motorcycle legally, be environmentally aware, and
respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used
components, comply with the laws and guidelines of the country in which you
are disposing of them.
Because motorcycles are not subject to the EU regulations governing the
disposal of used vehicles, there are no legal regulations that pertain to the
disposal of an end-of-life motorcycle. Your authorized dealer will be glad to
assist you.
2.9 Fitting instructions
It is important that you read these fitting instructions carefully and
completely before making your first trip. The fitting instructions contain
information and tips on how to operate, handle, and service your motorcycle.
This is the only way to find out how best to customize the vehicle for your
own use and how you can protect yourself from injury.
Keep the fitting instructions in an accessible place so you can refer to them
as needed.
If you would like to know more about the vehicle or have questions about the
instructions, please contact an aut- horized dealer.
The fitting instructions are an important component of the accessories and
must be handed over to the new owner if the vehicle is sold.
3.1 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner’s Manual and
specification.
3.2 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are
approved and/or recommended by KTM AG and have them installed by an authorized
workshop. KTM AG accepts no liability for other products and any resulting
damage or loss.
Certain spare parts and accessory products are specified in parentheses in the
descriptions. Your authorized dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: KTM.COM
The current Husqvarna Motorcycles accessories for your vehicle can be found on
the Husqvarna Motorcycles web-site.
International Husqvarna Motorcycles website:
www.husqvarna‑motorcycles.com
The current GASGAS Motorcycles accessories for your vehicle can be found on
the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
3.3 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may
not be shown at all. It is not always necessary to disassemble the component
to perform the activity in question. Please follow the instructions in the
text.
3.4 Customer service
Your authorized dealer will be happy to answer any questions you may have
regarding your vehicle and about KTM, Husqvarna Motorcycles or GASGAS
Motorcycles.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: KTM.COM
A list of authorized Husqvarna Motorcycles dealers can be found on the
Husqvarna Motorcycles website.
International Husqvarna Motorcycles website:
www.husqvarna‑motorcycles.com
A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS
Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
4.1 Scope of supply
1x Hand brake lever preassembled 1
1x Sleeve 2
1x Screw pin 3
1x Nut 4
ASSEMBLY
5.1 Assembly
– Remove nut 5.
– Remove cover 6 with the pin.
– Remove original hand brake lever.
Info
Ensure that spring 7 remains in place.
– Grease sleeve 2 and press in flush with hand brake
lever 1 (both included).
Long-life grease ( p. 10)
– Position hand brake lever 1 with spring 7.
– Mount screw pin 3 with lock nut 4 (both included) and tighten.
Guideline
| Screw connection, hand brake lever | 10 Nm (7.4 lbf ft) |
|---|
– The distance between the handle and hand brake lever can be adjusted to the
size of your hand by turning adjusting wheel 8.
Guideline
Do not make any adjustments while riding.
Info
The range of adjustment is limited. Only turn the adjusting screw by hand, and
do not use force.
– To adjust the lever length, loosen screw9.
– Move handle piece 9 to the required position.
– Tighten screw 9 .
Guideline
Ensure that the levers are correctly mounted.
Before riding for the first time, check that the brake works properly.
AUXILIARY SUBSTANCES
Long-life grease
Recommended supplier
MOTOREX®
– Bike Grease 2000
LIST OF ABBREVIATIONS
| 2 pieces | 2 pieces |
|---|
Art. no.
at least| Article number at least
ca.| circa
cf.| compare
cmpl.| complete
e.g.| for example
etc. i.a.| et cetera inter alia
no.| number
poss.| possibly
We are delighted that you have chosen this product. Our high-quality product
has been tried and tested for racing and specially developed for sporting
challenges. Correct assembly of the product is essential for guaranteeing the
maximum level of safety and functionality. Please follow the fitting
instructions or contact an authorized dealer.
The (quasi-)manufacturer or supplier cannot be held accountable for incorrect
assembly or usage of this product.
KTM AG is represented in the countries by:
– KTM Sportmotorcycle GmbH, Stallhofnerstrasse 3, 5230 Mattighofen, Austria
– Husqvarna Motorcycles GmbH, Stallhofnerstrasse 3, 5230 Mattighofen, Austria
– GASGAS Motorcycles GmbH, Stallhofnerstrasse 3, 5230 Mattighofen, Austria
The fitting instructions contain the latest information for this model series
at the time of going to print. However, minor differences due to further
developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. KTM AG specifically
reserves the right to modify or delete technical specifications, prices,
colors, forms, materials, services, designs, equipment, etc., without prior
notice and without specifying reasons, to adapt these to local conditions, as
well as to stop production of a particular model without prior notice. KTM AG
accepts no liability for delivery options, deviations from figures and
descrip-tions, misprints, and other errors. The models portrayed partly
contain special equipment that does not belong to the regular scope of supply.
© 2022 KTM AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only
with the express written permission of the copyright owner.
KTM AG
Stallhofnerstraße 3
5230 Mattighofen, Austria
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible
product quality as defined in the ISO 9001 international quality management
standard.
Issued by: TÜV Management Service
KTM
Sportmotorcycle GmbH
Stallhofnerstraße 3, 5230 Mattighofen
KTM.COM
Husqvarna Motorcycles GmbH
Stallhofnerstraße 3, 5230 Mattighofen
www.husqvarna‑motorcycles.com
GASGAS Motorcycles GmbH
Stallhofnerstraße 3, 5230 Mattighofen
http://www.gasgas.com