1993 kawasaki ZZR 250 Logo
Posted on Apr 20, 2010
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How do i remove my front wheel on my zzr250 - 1993 kawasaki ZZR 250

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  • Posted on Apr 29, 2010
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Joined: Apr 19, 2010
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First off you should remove the front caliper, there are two bolts holding that on the lower fork leg, once that is removed that you can loosen the axle and slide the axle out.

Pay close attention to the spacers and the speedo drive when you remove the axle so that you install everything proper when you put it back together.

Also you'll notice that the speedo drive only goes in one way, there are two tangs that need to be lined up on the receiver part of the hub, those have to slip into each other, if not you will damage your speedo drive.

Also before you start make sure you have something to hold the bike up since you will be pulling the front wheel out of it.

Torque the axle nut to 65 ft-lb
Torque the caliper bolts to 24 ft-lb

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Hi and welcome to FixYa,

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Dec 16, 2009 • 1992 kawasaki ZZR 250
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Dec 12, 2009 • 1993 kawasaki ZZR 250
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Dec 07, 2009 • kawasaki ZZR 250 Motorcycles
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I am trying to get the wheel assembly apart to change the front bearings on a 1996 mercury villiger
http://groups.yahoo.com/group/villagerquest/

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Item Part Number Description 1 — Cotter Pin 2 — Nut Retainer 3 1131 Insulator 4 3B477 Front Axle Wheel Hub Retainer 5 1195 Front Wheel Outer Bearing Retainer Washer 6 1104 Wheel Hub 7 1107 Lug Bolt 8 3K050 Snap Ring 9 3123 Front Wheel Bearing 10 2K004 Front Disc Brake Rotor Shield 11 3130 Front Wheel Knuckle

Wheel Hub, Wheel Knuckle and Wheel Bearing SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Tie Rod End Separator T85M-3395-A
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  2. Remove the wheel (1007) and tire assembly.
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  6. Remove the nut retainer and insulator.
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  8. Remove and discard the cotter pin from the front suspension lower arm ball joint (3050).
  9. Loosen the front suspension lower arm ball joint nut until it contacts the front wheel driveshaft joint.


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  10. Strike the front wheel knuckle with a hammer while pulling down on the front suspension lower arm (3078) until the front suspension lower arm ball joint separates from the front wheel knuckle.




  11. Remove the front suspension lower arm ball joint nut.




  12. Remove the front suspension lower arm ball joint from the front wheel knuckle.
  13. Remove and discard the cotter pin.




  14. Remove the tie rod end nut.




  15. Use Tie Rod End Separator T85M-3395-A to separate the tie rod end (3A130) from the front wheel knuckle.




  16. Remove the front brake anti-lock sensor bolt.




  17. Remove the two front shock absorber-to-front wheel knuckle nuts.




  18. Remove the two front shock absorber-to-front wheel knuckle bolts.
  19. Remove the front shock absorber (18124) from the front wheel knuckle.
  20. Use 2-Jaw Puller D80L-1002-L, or equivalent, to separate the front wheel driveshaft and joint (3B436) from the front wheel knuckle.
  21. Remove the front wheel hub, front wheel knuckle and front wheel bearing as an assembly from the vehicle.
  22. If necessary, match mark and remove the steering stop bolt and steering stop bolt jam nut from the front wheel knuckle.




Installation
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  1. Install the front wheel knuckle into the front shock absorber.
  1. Install the two front shock absorber-to-front wheel knuckle bolts.
  1. Install the two front shock absorber-to-front wheel knuckle nuts. Tighten the front shock absorber-to-front wheel knuckle nuts to 113-123 Nm (83-91 lb-ft).

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