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Trial/Cross: Rear wheel and chain removal and installation

WARNING!
  • For greater durability the KUBERG Trial/Cross chain does not use a removable chain master link, therefore the chain change includes removing the motor. KUBERG does not recommend splitting the chain in half while changing it with a new one because of its subsequently lowered durability and a mistake, that can be done very easily, when you don’t have sufficient mechanical knowledge, experience and proper tools.
  • Removing the motor requires partial wiring disconection. Therefore KUBERG highly recommends taking the motorcycle to your local selling dealer or to the nearest professional motorcycle service center. Making mistake during the disassembly or assembly of the electrical system will void the warranty and may cause a hazardous situation, resulting in fire, severe injury or death and damage to property.
  • For safety reasons it is strongly recommended to leave the battery discharged before handling any component of the motorcycle's electrical system

Follow these steps to remove the rear wheel:

Required tools:
  • hex wrench #3
  • brush with hard plastic bristles
  • soft cloth
  • brake disc cleaner
  • 219 chain wear indicator
  • 219 chain tension indicator
  • wrench #15
  • open wrench #10
  • 2 hex wrenches #5
  • cutting plier
  • hex wrench #8
  • Torx wrench #T25
  • red insulating tape
  • black insulating tape
  • sliding gauge
  • off-road motorcycle chain lubricant
  • zip ties (4 - 8 mm)
  1. Ensure, that the magnetic kill switch is in OFF position (magnet NOT attached) and the battery state of charge is very low.
  2. Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are off the ground.
  3. Using the hex wrench #3 loosen and remove 4 bolts holding the chain guard to the swingarm.



  4. Remove the chain cover from the motorcycle by a gentle sideways pull.
  5. Manually clean any dirt from the rear wheel, chain, spring-loaded chain tensioner, swingarm and brake calipers. A brush with hard plastic bristles and a soft cloth will be very useful here.
  6. Clean the motorcycle and let all the parts dry off completely, especially the chain. You can speed up this process by hand-spinning the wheels and using a soft cloth.
  7. Clean brake calipers with a soft cloth and both sides of brake discs with a suitable brake disc cleaner. 
  8. 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.
  9. Measure the chain’s wear using a 219 chain wear indicator.

    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 and let it prolong above the recommended limit, such chain may cause one or both sprockets to wear out extensively, so their change will be required altogether with the next chain change.

  10. Using the wrench #15 loosen the left and right nut on the rear wheel.
  11. 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).



  12. 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. You can ease this step by simultaneous gentle pull down on the spring-loaded chain tensioner roll below the motor.
  13. Remember the spacers’ position on both sides and carefully remove the rear wheel from the swingarm. Be aware, that removing the rear wheel will affect the position of the motorcycle’s center of gravity on the mounting stand.

    Following steps #14 - #40 describe the chain and motor removal and replacement. Skip to the step #41, if you don’t need to replace the chain.

  14. Carefuly cut the zip tie, fixing the rear brake hose to the swingarm.
  15. Bolster the rear tire to prevent the swingarm falling.
  16. Using a pair of the hex wrenches #5 loosen and remove the upper bolt and nut on the rear shock absorber
  17. Using the hex wrench #8 loosen and remove two side bolts on the swingarm axis, gently uninstall the swingarm from the motorcycle and put it close to the motorcycle due to the rear brake hose, that is still connected. Be careful and don’t twist the brake hose.
  18. (Only for Cross Hero): Using the hex wrench #6 loosen and remove the underseat bolt, located on the underside of the upper plastic bodywork (above the rear wheel), slide the seat forward and remove it from the motorcycle.
  19. Using the Torx wrench #T25 loosen and remove the upper 4 bolts from the upper plastic bodywork (2 on the left side + 2 on the right side).



  20. Remove the upper plastic bodywork by gentle pull up.
  21. Using the Torx wrench #T25 loosen and remove the 4 additional bolts from the left and right plastic bodywork (2 on the left side + 2 on the right side) and with a light frame tilt on the mounting stand remove both plastic bodyworks to access the motor.
  22. Remove the main red fuse from its socket.



  23. (Only for Lead-Acid battery):
    a) Check, whether the 2 cables, leading to the lower battery, have red and black ends (some older models did not have it). If not, use red insulating tape to mark the end of the cable, that leads to the positive pole of the battery, and use black insulating tape to mark the end of the cable, that leads to the negative pole of the battery. Optionally you can do the same with the upper batteries.
    b) Disconnect cables with red and black ending from the lower battery.
    c) Cut the zip tie and remove the velcro tape from the lower battery. Then gently pull the battery out from the frame.

    WARNING!
    Prevent any contact of the battery poles with the frame!


  24. Using the hex wrench #5 and the wrench #10 loosen and remove the lower motor bolt.
  25. Using the hex wrench #5 and the adjustable wrench repeat the same for the upper motor bolt.



  26. Slowly pull the motor backward for about 4" (10 cm) and check the spring-loaded chain tensioner, whether its spring, arms, bolts and nuts are fine, moving freely and everything is properly tightened (8 - 10 Nm).
  27. Remove the old chain and install the new one.
  28. Gently put the motor forward and reinstall the 2 bolts with their washers and nuts. Using the hex wrench #5 and the wrench #10/adjustable wrench tighten them (8 - 10 Nm).
  29. Reinstall the swingarm and apply a drop of threadlock on its 2 bolts. Using the hex wrench #8 tighten the two bolts (58 - 60 Nm).
  30. Pull the rear wheel up and align the upper mounting hole on the shock absorber with one of the mounting holes on the bracket (depending on the rider’s height) and install the bolt with its nut.
  31. Using 2 hex wrenches #5 tighten the bolt and its nut together (8 - 10 Nm).
  32. (Only for Lead-Acid battery):
    a) Return the lower battery onto its place in the frame, poles forward, and fix it firmly to the frame using the velcro tape and zip tie.

    WARNING!
    Prevent any contact of the battery poles with the frame!

    b) Reconnect the cable with the red ending to the positive pole of the lower battery. Double check, that the wiring is correct!
    c) Reconnect the cable with the black ending to the negative pole of the lower battery. Double check, that the wiring is correct!
  33. Reinstall the red fuse, removed in step #22, into its socket. A short and audible spark may appear during closing the circuit.
  34. With a light frame tilt to the right reinstall the left plastic bodywork, reinstall 2 lower bolts and using the Torx wrench #T25 tighten them (5 - 6 Nm).
  35. Repeat the same with the right plastic bodywork.
  36. Reinstall the upper plastic bodywork and align its 2 left holes with the upper holes on the left plastic bodywork and with the threads on the frame. Reinstall 2 bolts and using the Torx wrench #T25 tighten them (5 - 6 Nm).
  37. Repeat the same step on the right side.
  38. (Only for Cross Hero): Slide the front hole on the seat on the bolt, located close to the Torque & Speed control button. Align the thread in the seat with the rear hole in the upper plastic bodywork and with corresponding hole on the frame just above the rear wheel.
  39. (Only for Cross Hero): Install the seat bolt, removed in step #18, and using the hex wrench #6 tighten it (16 - 18 Nm).
  40. Use a zip tie to safely fix the rear brake hose to the swingarm and ensure, that neither the brake hose, nor the zip tie cannot get in contact with the rear wheel.

    Follow these steps to reinstall the rear wheel:

  41. Check, that the rear axle spins freely in the hub.
  42. Carefully insert the rear wheel back into the swingarm, with all spacers in the same grouping as before the uninstallation. The brake disc must slide easily between the brake pads. Be aware, that adding the rear wheel to the motorcycle will affect the position of the motorcycle’s center of gravity on the mounting stand.
  43. Push the rear wheel forward, slowly spin it by hand and load the chain onto the sprocket. Also check, that the chain is loaded correctly into the main chain tensioner’s roll.
  44. 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. During loosening the tensioners regularly gently push the rear wheel forward, for both tensioners to stay in contact with the rear end of the swingarm.
  45. Continuously measure the distance between the spring-loaded chain tensioner’s roll and the the swingarm, which should be 0.2 – 0.4“ (5 - 10 mm). The roll must not be able to touch the swingarm during its up and down movement.



    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, buy a 219 chain tension indicator. The spring-loaded chain tensioner, located below the motor, helps to keep the chain tension in optimal values, but for its correct operation a proper distance of the rear wheel to the motor is required. Additionally if the spring is damaged, the spring-loaded chain tensioner will not be able to preload the chain sufficiently.

  46. Using the wrench #15 tighten both left and right nut of the rear wheel (24 - 26 Nm).
  47. 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.



  48. While hand-spinning the rear wheel, lubricate the cleaned chain in the area behind the spring-loaded chain tensioner 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.
  49. Spray a small amount of lubricant on the spring-loaded chain tensioner’s pivots and bearings and ensure, that it moves up and down smoothly. Remove excess lubricant 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.

  50. Reinstall the chain cover and using the Allen wrench #3 tighten all 4 bolts, that hold the chain cover on the swingarm (3 - 4 Nm).
  51. Double check, that all bolts and nuts are properly tightened.

If you want to change the chain by splitting it (not recommended), skip the steps #11 - #42 and follow this method instead:
  1. Grind off one chain pin, so it’s completely flush and only the friction is holding the pin in.
  2. Use a chain splitter tool to split the old chain.
  3. Repeat the same for the new KUBERG Trial/Cross chain, which comes in one piece, and remove 2 adjacent pins on the wider chain link.
  4. Install the new chain, load it into the spring-loaded chain tensioner and connect its free ends with the lubricated rivet master link (sold separately).
  5. Use a chain riveter to fasten the rivet master link on the new chain.
  6. Using the digital caliper make sure, that the rivet master link width is the same as the width of any other link on the chain. Use a chain riveter again if necessary.
  7. Follow steps #43 up to the end (see above).
WARNING!
The rivet master link must move freely on the chain, otherwise it can lock the rear wheel and cause an accident!


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


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