Ranger: Front and rear wheel removal and installation

Table of contents:

Front wheel removal and installation
Rear wheel removal and installation

1. Front wheel removal and installation

Follow these steps to remove and install the front wheel:

Required tools:

hex wrench #5
hex wrench #6
hex wrench #10
open wrench #10
wrench #24
brush with hard plastic bristles (for muddy motorcycles)
soft cloth
brake disc cleaner

Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached).
Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are off the ground.
Manually clean any dirt from the front wheel, front suspension fork, brake caliper and brake disc. A brush with hard plastic bristles and/or a soft cloth will be very useful here.
Clean the brake caliper with a soft cloth and both sides of brake discs with a suitable brake disc cleaner.
Inspect the front wheel, front suspension fork, brake caliper and brake disc for any damage. If found any, please contact Your local selling dealer or the KUBERG Customer Service. Also check, whether the brake surface thickness of any brake pad is at least 0.03” (0.8 mm), otherwise a brake pads change is required.
(Only for Dorado Comp): Using the hex wrench #5 loosen the locking axle bolt, located on the brake-disc side of the fork
(Only for Dorado Exp): Using the hex wrench #6 loosen and remove the locking axle bolt, located on the brake-disc side of the fork.
Using the hex wrench #5 loosen 4 front axle bolts, located on the bottom of the front fork.
While holding the front wheel, slowly remove the axle and both spacers and lower the wheel carefully away from the front fork. From this point on do not press the front brake lever, until the front wheel assembly is complete.

CAUTION!
Be aware, that removing or adding the front wheel will affect the positon of the motorcycle’s center of gravity on the mounting stand.

Follow these steps to reinstall the front wheel:

NOTE:
For greater clarity of the assembly process please see this video https://youtu.be/ZmzBZhK3KSk
Check, that the front hub spacer is coaxial with both bearings and insert the front wheel and both spacers carefully into the front fork. The brake disc must slide easily and gently between brake pads. Lubricate the front axle with appropriate ammount of designated lubricant, then slowly slide the axle into the front hub.
(Only for Dorado Comp): Insert the axle locking bolt and using the hex wrench #6 tighten it (3,4 - 4,5 Nm).
(Only for Dorado Exp): Using the hex wrench #5 tighten the axle locking bolt (12 - 15 Nm).
Remove the motorcycle from mounting stand and with just the rear brake engaged spring the front suspension fork several times for the wheel axle to settle in the suspension fork.
(Only for Dorado Comp): Using the hex wrench #6 retighten the axle locking bolt (3,4 - 4,5 Nm).
(Only for Dorado Exp): Using the hex wrench #5 retighten the axle locking bolt (12 - 15 Nm).
Using the hex wrench #5 slowly and alternately tighten all 4 axle bolts (10,7 - 12,4 Nm).
Ensure, that the wheel is aligned correctly and all bolts are tightened properly.
Spin the front wheel to ensure, that it is centered and spins freely. If not, go to manual and follow the brake adjustment instructions.

2. Rear wheel removal and installation

Follow these steps to remove and install the rear wheel:

Required tools:

hex wrench #5
hex wrench #10
open wrench #10
wrench #24
brush with hard plastic bristles (for muddy motorcycles)
soft cloth
brake disc cleaner
219H chain wear indicator
219H chain tension indicator

Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached).
Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are off the ground.
Inspect both sprockets, chain and spring-loaded chain tensioner for any damage. If found any, please contact Your local selling dealer or the KUBERG Customer Service.
Using the 219 chain wear indicator check the secondary chain. If the chain needs to be replaced, find more information about the chain removal and installation in the Ranger manual.

CAUTION!
Do not wait with the chain change for the last possible moment - better sooner than later. If You don’t change the chain in time, the rear sprocket or double sprocket may wear out extensively, so the change of one or both of them will be required altogether with the chain change. The same apply for the primary chain.
Using the hex wrench #10 and the open wrench #24 loosen and remove the rear axle nut. Don’t remove the rear axle yet.
Using the open wrench #10 loosen both rear wheel tensioners almost entirely for the rear wheel to be able to move forward about 0.5“ (1.25 cm).
Slowly spin the rear wheel and gently pull the chain to the outer side of the sprocket. The chain should slip sideways without much effort.
Remember the spacers’ position on both sides and while holding the wheel, slowly remove the rear axle, spacers and washers on both sides.
Carefully remove the rear wheel from the swingarm. From this point on do not push the rear brake lever, until the assembly is complete.

CAUTION!
Be aware, that removing or adding the front wheel will affect the positon of the motorcycle’s center of gravity on the mounting stand.

Follow these steps to reinstall the rear wheel:
Check, that the rear hub spacer is coaxial with both bearings and insert the rear wheel and all spacers carefully into the swingarm. The brake disc must slide easily and gently between brake pads. Then slowly slide the axle into the rear hub.
Install the axle nut, but do NOT tighten it yet.
Push the rear wheel forward, slowly spin it by hand and load the chain onto the sprocket.
Using the wrench #10 slowly and alternately tighten both rear wheel tensioners, while still maintaining a straight position of the rear wheel relative to the shock absorber, which will also keep the chain line straight for the chain to move correctly and safely. During tightening the tensioners it’s not necessary, but during their loosening regularly gently push the rear wheel forward, for both tensioners to stay in contact with the rear axle. Set the correct chain tension.

WARNING!
Proper chain tension and straight chain line are important for its lifespan and rider safety and can also prolong the riding time. Do not tighten the chain too much - if the chain is overtightened, it will be loud, it will wear out quicker and also shorten riding time. If the chain is too loose, it may fall off the rear sprocket and cause an accident. To be absolutely sure, that the chain tension is set correctly, use a 219H chain tension indicator.
Using the hex wrench #10 and the open wrench #24 tighten the rear axle nut (68 - 70 Nm).
Check, whether the whole braking surface of the rear brake pads is in contact with the rear brake disc, when the rear brake lever is pushed. If not, using the hex wrench #5 loosen 2 side bolts, holding the rear brake caliper adapter on the swingarm, and move the rear brake caliper forward or backward to increase the braking surface to its maximum.
Spin the rear wheel to ensure it is centered and spins freely. If not, follow the brake adjustment instructions in the Ranger manual.
While hand-spinning the rear wheel, lubricate both chains in the area behind the double sprocket with an appropriate off-road motorcycle chain lubricant. Wait a minute for a lubricant to dry off, then remove excess lubricant from the chain with a soft cloth.

WARNING!
Prevent contact of the lubricant with the tire, brake calipers and discs - it would have a major negative impact on the braking force! It probably won’t be sufficient to brush the brake pads with sandpaper and very often new brake pads are required.
Double check, that all bolts and nuts are properly tightened.

If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration

If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:

VIN of Your motorcycle (it is stamped on the right side of the steering column).
Detailed information on actions taken so far, a few photos and preferably a video.

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Ranger: Front and rear wheel removal and installation

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