Dismounting And Mounting The Front Wheel; Dismounting And Mounting The Rear Wheel - KTM 640 DUKE II 2003 Owner's Manual

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Dismounting and mounting the front wheel*

To remove the front wheel, jack the motorcycle up by the frame so that the
front wheel no longer touches the ground.
Take out both AH screws
!
W
HEN REMOVING THE BRAKE CALIPER
DISC AND THE BRAKE LININGS ARE NOT DAMAGED
Screw speedometer cable
Loosen the clamp screws
clamp screws on the left fork fist tightened).
4
Loosen wheel spindle
Hold the front wheel, pull the wheel spindle out, remove the front wheel
from the fork by pulling it forward.
!
– D
O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN REMOVED
– A
LWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT
DAMAGING OF THE BRAKE DISC
Prior to mounting the front wheel, clean and grease the shaft seal ring
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and running surface
To mount the front wheel insert speedometer drive into the front wheel.
Lift the front wheel into the fork and position the speedometer drive as
shown in the illustration (the connection for the speedometer cable must be
below the nose 7 .
Replace the wheel spindle and tighten it with 40 Nm (30 ft.lb).
Mount the brake caliper, apply Loctite 243 to the thread of the allan head
screws and tighten it 45 Nm (33 ft.lb).
Attach speedometer drive cable.
Jack the motorcycle back down, work the front brake and bounce the fork
hard a few times to align the fork tubes.
Now you can tighten the clamp screws on the right fork leg axle passage to
10 Nm (7 ft.lb).
1
– T AH
HE SCREWS OF THE BRAKE CALIPER MUST BE SECURED WITH
TO PREVENT LOOSENING
– I '
F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND
THE TIGHTENING TORQUE CORRECTED BY A
– I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE
WISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED
– A
FTER MOUNTING THE FRONT WHEEL
PRESSURE POINT RETURNS

Dismounting and mounting the rear wheel*

Jack up the motorcycle under the frame to lift the rear wheel of the ground.
Remove the hexagon nut
Loosen the AH screw
out on the left side. Remove the brake caliper from the brake disk.
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Hold the rear wheel and remove the wheel spindle. Move the rear wheel
down and forward and take the chain off of the rear sprocket.
!
– D
O NOT OPERATE THE FOOT BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED
– A
LWAYS PUT DOWN THE WHEEL WITH THE BRAKE DISC ON TOP TO PREVENT
DAMAGING OF THE BRAKE DISC
NOTE:
When removing the rear wheel always check the damping rubbers.
Clean and lubricate the wheel spindle thread.
Lift the rear wheel together with the rear sprocket carrier into the swinging
fork and place the chain on the rear sprocket.
Insert the wheel spindle to hold the rear wheel and position the brake cali-
per. Align the eccentric and tighten the wheel spindle to 80 Nm (59 ft.lb).
Tighten the hexagon nut to 40 Nm(30 ft.lb) and the AH screw on the brake
caliper to 40 Nm(30 ft.lb).
– I '
F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND
THE TIGHTENING TORQUE CORRECTED BY A
– I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE
OTHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED
– A
FTER MOUNTING THE REAR WHEEL
PRESSURE POINT RETURNS
1 and remove brake caliper from brake disc.
CAUTION
,
MAKE SURE THAT THE BRAKE LINE
.
2 from speedometer drive.
3 on the right fork leg axle passage (leave the
.
CAUTION
.
at the speedometer drive.
WARNING
.
KTM
DEALER AS SOON AS POSSIBLE
,
KEEP OPERATING THE HAND BRAKE UNTIL THE
.
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on the left swing arm fist.
9 bk
and the wheel spindle
CAUTION
.
WARNING
KTM
DEALER AS SOON AS POSSIBLE
,
KEEP OPERATING THE FOOT BRAKE UNTIL THE
.
!
,
THE BRAKE
!
.
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L 243
OCTITE
,
MAKE SURE YOU HAVE
.
, -
OTHER
.
bl
and pull the eccentric
!
.
,
MAKE SURE YOU HAVE
.
,
.