Removing the front wheel
Preparatory work
- Raise the motorcycle with the rear lifting gear.
- Lift the motorcycle with the front lifting gear.
Main work
- Remove screws 1 with washers and push the fender slightly to the side.
- Remove screw 2 and pull wheel speed sensor 3 out of the hole.
- Loosen screw 4 by several rotations.
- Loosen screws 5.
- Remove screw 4.
Warning Danger of accidents: Reduced braking effect caused by damaged brake discs. – Always lay the wheel down in such a way that the brake discs are not damaged.
- Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork
Info Do not pull the hand brake lever when the front wheel is removed.
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep brake discs free of oil & grease.
- Clean them with brake cleaner when necessary.
- Check the wheel bearings for damage and wear.
- If the wheel bearing is damaged or worn: Change the wheel bearing.
- Remove the spacers.
- Clean and grease the shaft seal rings 1 and and contact surfaces A of the spacers.
Long-life grease
– Insert the spacers.
- Clean the thread of the wheel spindle and screw 2.
- Clean and grease wheel spindle.
Long-life grease
- Position the front wheel and insert the wheel spindle.
- The brake linings are correctly positioned.
- Mount and tighten screw 2.
| Guideline | ||
| Screw, front wheel spindle | M8 | 25 Nm(18.4 lbf ft) |
- Mount and tighten screw 4.
| Guideline | ||
| Screw, wheel speed sensor holder | M6 | 8 Nm (5.9 lbf ft) |
| Guideline | ||
| Screw, front fender | M6 | 7 Nm (5.2 lbf ft) |
- Take the motorcycle from the front lifting gear.
- Remove the rear of the motorcycle from the lifting gear.
- Operate the front brake and compress the fork a few times firmly. The fork legs straighten.
- Tighten screws 6
| Guideline | ||
| Screw, fork stub | M8 | 15 Nm (11.1 lbf ft) |
Removing the rear wheel
Preparatory work
- Raise the motorcycle with the rear lifting gear.
Main work
- Remove screw 1
- Remove nut 4 and washer.
- Remove chain adjuster 5.
- Holding the rear wheel, withdraw wheel spindle 6 with the washer and chain adjuster 5.
- Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
- Push chain guard to the side.
Warning
Danger of accidents Reduced braking effect caused by damaged brake discs.
- Always lay the wheel down in such a way that the brake disc are not damaged.
Info Do not operate the foot brake lever when the rear wheel is removed.
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean them with brake cleaner when necessary.
Warning
Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
- Actuate the foot brake several times before going on a ride until you can feel a firm pressure point.
Main work
- Check the wheel bearing for damage and wear.
- If the wheel bearing is damaged or worn.
- Change the wheel bearing.
-Remove the spacers.
- Clean and grease shaft seal rings 1 and contact surfaces A of the spacers.
| Long-life grease. |
- Clean and grease wheel spindle.
| Long-life grease. |
- Mount the rubber damper and rear sprocket carrier on the rear wheel.
- Insert the spacers.
- Position the rear wheel.
- The brake linings are correctly positioned.
- Push the rear wheel forward as far as possible and lay the chain on the rear sprocket.
- Position the chain guard.
| Nut, rear wheel spindle | M 14x1.5 | 98Nm |
Checking the rear hub rubber dampers
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
- Remove the rear wheel.
- Check bearing 1.
- If the bearing is damaged or worn.
- Change the bearing.
- Check rubber dampers 2 of the rear hub for damage wear
- If the rubber dampers of the rear hub are damaged or worn.
- Change all rubber dampers in the rear hub.
- Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub.
- To check the play A, hold the rear wheel tight and try to rotate the rear sprocket.
- Play in rubber dampers, rear wheel < 5 mm.
- If clearance A is larger than the specified values.
- Change all rubber dampers in the rear hub.
- Install the rear wheel.
Info
Measure the play on the outside of the rear sprocket.
- In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help).
Warning Danger of accidents Poor vehicle handling due to different tire tread patterns on front & rear wheels.The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.Only tires/wheels approved by KTM & with corresponding speed index should be used.
Info
The type, condition & air pressure of the tires all have a major impact on riding behavior of motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces.
- Check the front and rear tires for cuts, run-in objects, and other damage.
- If the tires have cuts, run-in objects, or other damage:
- Change the tires.
- Check the depth of the tread.
- Minimum tread depth > 2 mm.
- If the tread depth is less than the minimum permissible depth.
- Change the tires.
- Check the age of the tires.
- If a tire is more than 5 years old
- Change the tire.
Info
Note local national regulations concerning the min. tread depth
Info
The tire's date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.
Material damage Incase the motorcycle is fitted with imported tires, compliance to respective Indian standard & central motor vehicle rules has been ensured.
Checking the tire air pressure
Info
- Low tire air pressure leads to abnormal wear and overheating of the tire.
- Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
- Remove the dust cap.
- Check tire air pressure when the tires are cold.
- If the tire air pressure does not meet specifications.
- Correct the tire air pressure & mount the dust cap.
| Tire air pressure | |
| Front | 28.5 psi (2 kg / cm2) |
| Rear Solo | 28.5 psi (2 kg / cm2) |
| Rear Pilion | 32 psi (2.20 kg / cm2) |
