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Thread: KGT Wheel Removal (2009)

  1. #46
    Honey Badger Semper_Fi's Avatar
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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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  2. #47
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    Rear Wheel Removal

    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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    Last edited by Semper_Fi; 06-14-2010 at 09:24 PM.

  3. #48
    Honey Badger Semper_Fi's Avatar
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    There is a tongue and groove interface feature on the back side of the guard
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  4. #49
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    Loosen Exhaust clamp using a T45 torx
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    Last edited by Semper_Fi; 06-14-2010 at 09:24 PM.

  5. #50
    Honey Badger Semper_Fi's Avatar
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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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  6. #51
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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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    Last edited by Semper_Fi; 06-14-2010 at 09:26 PM.

  7. #52
    Honey Badger Semper_Fi's Avatar
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    Put the bike in gear and remove the wheel bolts using a T-50
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  8. #53
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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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    Last edited by Semper_Fi; 06-14-2010 at 12:33 AM. Reason: Rear Tire Replacement

  9. #54
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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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    Last edited by Semper_Fi; 06-14-2010 at 09:27 PM.

  10. #55
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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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  11. #56
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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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  12. #57
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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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    Last edited by Semper_Fi; 06-14-2010 at 09:40 PM.

  13. #58
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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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    Last edited by Semper_Fi; 06-14-2010 at 12:50 PM.
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  14. #59
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    Done!!
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