KGT Wheel Removal (2009)

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Using a T45 loosen the right (Throttle) side pinch bolt ONLY.

DO NOT LOOSEN OR REMOVE THE CLUTCH SIDE PINCH BOLT AS THIS AFFECTS THE ALIGNMENT OF THE WHEEL

 

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Use an axle removal tool to remove the axle.

This tool from Marc Parnes is used in conjuction with a 19mm wrench or socket

 

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As I did not want to loosen the axle when the wheel was in the air, I am breaking it free here before the lift.

 

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Prior to lifting make sure the ABS Sensor and Wire are clear of the lift points where the wheel stand will contact the fork legs indicated by the green arrow.

 

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While loosening/removing the quick release axle - support the wheel assembly to aid in the removal process.

 

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Unscrew and remove the axle.

 

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Pull the wheel off - pay attention to the rotors and fork tubes, it will be a little snug but will come out.

 

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This is the clutch side view of the spacer in the fork which should NOT have its pinch bolt loosened or removed

 

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After a day's rest my new tires were mounted on the bike.

Two things to be aware of, most tires are directional, meaning they need to be mounted in a specifc manner to maximize the thread design.

The is a mark on the tire that indicates how is should be mounted on the bike.

Shown below is one such mark - green cricle highlight

The other thing to confirm directionality is that the ABS ring of the wheel goes on the Clutch side

 

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Shown here is the tire in place, but not secured.

A 5 step process, of which shown is 1 thru 4

1. Insert tire in the correct orientation in between the fork legs
   
2. Work the brake disks and ABS ring into position without damaging the disks, ring or fork legs. (Not difficult to do just need to go slow and be carefull)
   
3. Once the hub center is in line to the axle placement, lift the wheel up to meet the axle as it is being passed thru the left (Throttle) side fork leg - Green Arrow
   
4. Manually turn the axle to ensure proper thread engagement
   
5. Tighten to spec

 

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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