Ben Reingold / Boise, ID
I’ve found that the rear brake lever on most, if not all, KTMs is designed somewhat poorly. It’s not a matter of “if” but “when” it will eventually hit the sidecase to mar up the aluminum and create a hole or crack. I’ve personally witnessed another rider punch a hole in the case as a result of a healthy bang from a rock on the brake lever and then lose oil on the trail—bad deal. I own a 2006 KTM 450 EXC and quite some time ago put a preventative measure in place to avoid this problem. First, file away, at an angle, the first set of teeth near the case. Next, use a small piece of scrap rubber tubing and cut it so that it form-fits the brake pedal facing the case. Cut two holes so that the two bolts hold it in place and you’re done. Another quick tip is to use slick nylon tape (for dresser drawers) and place it on the lower portion of the sidecase for protection. The adhesive property of this stuff is amazing.
On my friend’s 2010 KTM 530 ISDE, we removed the brake pedal by taking off two small bolts and sliding a piece of rubber hose on the shaft. The hose will not slide back because the shaft gets wider.