KGT Wheel Removal (2009)

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After a few pumps the pads are set in the front caliper and you will have proper lever action to safely activate the brakes.

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Removal process:

1. Remove Exhaust pipe cover guard
2. Loosen Exhaust clamp
3. Remove Exhaust Hanger Bolt
4. Remove exhaust
5. Remove Wheel

Starting with the Exhaust pipe cover guard use a T25 to remove

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There is a tongue and groove interface feature on the back side of the guard

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Loosen Exhaust clamp using a T45 torx

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After you have loosened the clamp you need to remove the Exhaust hanger bolt.

CAUTION - ensure you are supporting the exhaust as this is the last mechanical securing item

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SHOP TIP - After you remove the muffler you will have the exhaust system open - to prevent any foreign material to fall in you may want to stuff a rag to prevent such an occurrence.

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Put the bike in gear and remove the wheel bolts using a T-50

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The replacement process for the rear wheel is as follows

1. Install wheel onto rear hub
2. Install Wheel Lugs and torque to spec
3. Install muffler
4. Mount hanger
5. Tighten exhaust clamp
6. Install exhaust cover shield

IMPORTANT NOTE - The Wheel bolts DO NOT get any lubricant or locking material applied to them, they go in dry, they come out dry

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Below shows the tire mounted onto the rear hub.

The wheel bolts have been put in, hand tight, ensuring the wheel is properly seated then torque as outlined.

The torquing sequence is a diagonal pattern shown below:

1 to 2

2 to 3

3 to 4

4 to 5

Tighten to 60Nm (44 ft-lbs)

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The next step is mounting the muffler, it is a two step process.

The first mouting is the muffler onto the exhaust opening (Green arrow) and then swinging the muffler up onto the top mount location (Blue Arrow).

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Mount the muffler handing bolt hand tight as you need to ensure that the muffler is properly spaced to the rear wheel.

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Ensure that there is 10mm of spacing between the muffler and the rear wheel

Shop Tip - by having the muffler hanger and muffler clamp hand snug - you can position the muffler to be in the proper alignment before completely tightening.

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Once the spacing is set tighten the muffler clamp to 35Nm (26 ft-lbs)

Then tighten the muffler hanger to 22Nm (16 ft-lbs)

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Done!!