990 smt rear master cylinder problem

Here be mechanigeeks. Anything technical that is not a teething problem.
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MastrUsr
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990 smt rear master cylinder problem

Post by MastrUsr » Tue Jun 11, 2019 10:36 am

Hello!
Yesterday I were out sliding the bike and unfortunately just hit some grass at the edge of the gravel road and skid down on the right side at about 30km/h.

Anyhow. The only real problem was that the foot pedal got caught and ripped the push rod out (RED on pic).

Colors refer to arrows pointing on actual part.

RED got ripped downwards by "pulling" the brake pedal upwards.
BLUE that i guess is supposed to hold the RED in place got bent and wont hold it anymore.
GREEN i suppose is to keep oil or something in?

Anyways. I think the thing is leaking slightly and I can pull the piston (PURPLE) out (I'm not sure if this leaking is due to the piston getting to far out). Do you think that I can just get a new RED and GREEN and be done with it? Do you think there is a "big" chance that there will be leaks unless i buy new assemblies (number 4 and 5 on the picture)?

Image



Also, is there any mod you know of to prevent this form happening again?

Best regards,
Eric

Magic Wand
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Re: 990 smt rear master cylinder problem

Post by Magic Wand » Tue Jun 11, 2019 10:58 am

PM sent
(PM till dig Eric)

/M

MastrUsr
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Re: 990 smt rear master cylinder problem

Post by MastrUsr » Tue Jun 11, 2019 2:18 pm

After some googling it seems that the rod is actually supposed to be "stuck" at the piston. I also found out that KTM seems to have moved away from this design because of exactly what happened to me. This seems to only have been done to the Adventure models though. Can anyone confirm?

See pics here:
http://www.v-duo.co.uk/wp-content/uploa ... 90-2-2.jpg

and here:
https://f.allegroimg.com/original/0c431 ... 38f5b2843f

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limeyduffa
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Re: 990 smt rear master cylinder problem

Post by limeyduffa » Wed Jun 12, 2019 2:40 am

Hi Mate

Due to the age of your bike, I would service the whole master brake system and be done with it. Having never done this job before, this would be my approach:

5 600 13 061 000 REPAIR KIT PISTON 03 x1

If the push rod is bent or damaged, then:

4 600 13 056 044 PUSH ROD CPL. '03 x1

Another option is an after market solution since (in my opinion) the rear brake on the SMT feels like that from an early model Hyodung GT650. You might be lucky. Contact some motorcycle brake specialists in your city.

Either way, do a write up of your repair with pics and post it up on here :)

MastrUsr
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Re: 990 smt rear master cylinder problem

Post by MastrUsr » Wed Jun 12, 2019 12:48 pm

We'll see. I have a race bike that need some attention too (read money :?). I didn't find any problem with the rear brake, though I am riding with road tires on gravel so a light push and engine braking will slide the rear. I think I'll try the cheap way first...
I found that the SMT have the same rear brake system as the 03 - 07 Adventure..

I'm interested in going the route with some form of pedal stop instead of fixating it to the brake piston.. I'll see what I come up with and maybe I'll post some pictures. :) Sadly I can't access this forum on tapatalk which makes it more bothersome.

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