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Kawasaki KLE500-B1 2004 Service Manual.doc
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Caution

Never lubricate with engine oil or petroleum distil­lates because they will deteriorate the tire.

• Break the beads away from both sides of the rim with the bead breaker [A].

Special Tool - Bead Breaker Assembly: 57001-1072

WHEELS/TIRES 10-11

Tires

• Step on the side of the tire opposite valve stem, and pry the tire off the rim with the tire iron [B] of the bead breaker protecting the rim with rim protectors [A].

Special Tools - Rim Protector: 57001-1063

Bead Breaker Assembly: 57001-1072

Caution

Take care not to insert the tire irons so deeply that the tube gets damaged.

  • Remove the tube when one side of the tire is pried off.

  • Pry the tire off the rim.

  • Remove the rim protector.

Tire Installation

  • Inspect the rim and the tire before installing the tire, and replace them if necessary.

  • Apply a soap and water solution or rubber lubricant to both the tire bead and the rim flange.

  • Check the tire rotation mark on the front and rear tires and install them on the rim accordingly.

Rotation Direction [A] Tire Rotation Mark [B]

IPnosstaitlilotnhethteiretirine tohne trheeverirmsesoordthear totfhreemvaolvvael.stem [A] is

at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). ○Adjust the air pressure to the specified pressure (see Air Pressure Inspection/Adjustment in the Periodic Mainte­nance chapter). Tighten the value stem nut securely.

  • Install the air valve cap.

  • Install the brake disc(s) so that the marked side faces out (see Brakes Disk Installation in the Brakes chapter). Adjust the wheel balance.

10-12 WHEELS/TIRES

Hub Bearing

Hub Bearing Removal Remove the wheel, and take out the following.

Caution

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.

Front

Grease Seal [A] Circlips [B]

Special Tool - Inside Circlip Pliers: 57001-143

Rear

Coupling [A] Collar [B] Circlip [C]

Special Tool - Inside Circlip Pliers: 57001-143

• Take the bearings [A] out of the hub, using the bearing remover.

Special Tools-Bearing Remove Shaft: 57001-1377 [B]

Bearing Remover Head, 015 × 17: 57001

-1267 [C] Oil Seal & Bearing Remover: 57001-1058

Hub Bearing Installation

  • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings.

  • Replace the bearings with new ones.

IPnrsetsasll itnhethferolnetftbseidaerinbgesairnintghe[Af]oullonwtilinitgissbeoqtutoemnceed. .

○Insert the collar [B] in the hub [C].

○Press in the right side bearing [D] until it is bottomed.

Special Tool - Bearing Driver Set: 57001-1129

IPnrsetsasll itnhethreearirgbhet asridinegbseinartihneg fuonlltoilwitinisgbsoetqt oume necde. .

○Insert the collar in the hub.

○Press in the left side bearing until it is bottomed.

Special Tool - Bearing Driver Set: 57001-1129

NOTE

Install the bearings so that the marked side or sealed side faces out.

• Replace the circlips with new ones.

Special Tool - Inside Circlip Pliers: 57001-143

WHEELS/TIRES 10-13

Hub Bearing

Hub Bearing Inspection

Since the hub bearings are made to extremely close tol­erances, the clearance cannot normally be measured.

NOTE

О Do not remove any bearings for inspection. If any bear­ings are removed, they will need to be replaced with new ones.

  • Turn each bearing in the hub back and forth [A] while checking for plays, roughness, or binding.

  • If bearing play roughness, or binding is found, replace the bearing.

  • Examine the bearing seal [B] for tears or leakage.

  • If the seal is torn or is leaking, replace the bearing.

Hub Bearing Lubrication

• Clean and grease the rear left side hub bearing in accor­ dance with the Periodic Maintenance chapter.

NOTE

О Since the front and rear hub bearings are packed with grease and sealed, lubrication is not required.

10-14 WHEELS/TIRES

Speedometer Gear

Disassembly and Assembly

NOTE

It is recommended that the assembly be replaced rather than attempting to repair the components.

• Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).

Lubrication

• Clean and grease [A] the speedometer gear housing [B] in accordance with the Periodic Maintenance chapter.

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