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Thread: KGT Wheel Removal (2009)

  1. #31
    Honey Badger Semper_Fi's Avatar
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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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    Last edited by Semper_Fi; 06-14-2010 at 08:18 PM.

  2. #32
    Honey Badger Semper_Fi's Avatar
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    Now torque the axle to its specified value of 50Nm (37 ft-lbs)
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    Last edited by Semper_Fi; 06-19-2010 at 08:02 PM.

  3. #33
    Honey Badger Semper_Fi's Avatar
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    Tighten the loosened pinch bolt and torque to 19Nm (14 ft-lbs)
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    Last edited by Semper_Fi; 06-19-2010 at 08:03 PM.

  4. #34
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    Install ABS Sensor, ensuring proper routing of sensor wiring
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  5. #35
    Honey Badger Semper_Fi's Avatar
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    Secure ABS sensor with mounting bolt
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  6. #36
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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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    Last edited by Semper_Fi; 06-14-2010 at 08:22 PM.

  7. #37
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    Install the caliper bolts and thread them in confirming proper thread engagement.
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  8. #38
    Honey Badger Semper_Fi's Avatar
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    Torque to 30 Nm (22 ft-lbs)
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  9. #39
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    Attach ABS Sensor wire clips onto brake line
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  10. #40
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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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  11. #41
    Honey Badger Semper_Fi's Avatar
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    Ensure proper thread engagement of the caliper bolts and torque to 30 Nm (22 ft-lbs)
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  12. #42
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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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  13. #43
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    Mount the fender.
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  14. #44
    Honey Badger Semper_Fi's Avatar
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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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    Last edited by Semper_Fi; 06-14-2010 at 08:23 PM.

  15. #45
    Honey Badger Semper_Fi's Avatar
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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!!
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