KGT Wheel Removal (2009)

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Tighten the axle until hand tight and this will be enough to support the wheel assembly and the bike so that you can torque the axle to spec after the bike is lowered off the stand.

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Now torque the axle to its specified value of 50Nm (37 ft-lbs)

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Tighten the loosened pinch bolt and torque to 19Nm (14 ft-lbs)

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Install ABS Sensor, ensuring proper routing of sensor wiring

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Secure ABS sensor with mounting bolt

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Working from the clutch side install clutch side caliper.

Come in at and angle and "wrap" the caliper in place onto the brake disc

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Install the caliper bolts and thread them in confirming proper thread engagement.

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Torque to 30 Nm (22 ft-lbs)

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Attach ABS Sensor wire clips onto brake line

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Repeat caliper install with the throttle side caliper, again coming in from an angle to mount the caliper

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Ensure proper thread engagement of the caliper bolts and torque to 30 Nm (22 ft-lbs)

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Prior to installing the fender back on you may want to check the threads as mine were slightly corroded.

I chased the threads with an M6 x1.0 Tap

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Mount the fender.

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CRITICAL FINAL STEP

You need to pump the front brake lever to set the caliper pucks back position onto the discs for the brakes to work correctly

Shown below is the very first pump action - as you can see the brake lever is at its normal position

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Now the lever is pumped and reaches all the way to the bar.

That is why you do this in the garage and not on the road!!