How to Take the Front Tire Off a 2010 Kawasaki Vulcan 900

by TJ Hinton

Kawasaki produced the 2010 Vulcan 900 series with a 903 cc, rubber mounted, liquid cooled, four-valve-head, V-twin engine. The Electronic Control Unit provides precise throttle response and control through the fuel injection system. The 41 mm front fork tubes, and a magnesium-cast front wheel, provide rigidity and resistance to flexing of the steering components, which provides stability in curves and over rough road surfaces. Trim variants for the Vulcan 900 emphasize the "custom" details that are available.

Removal

1

Park the bike on firm, level ground, and rest it on the sidestand. Turn the front forks to the full right turn position.

2

Remove the two brake caliper mounting bolts from the lower fork, using a ratchet and socket. Remove the caliper from the lower fork and suspend it, using a bungee cord. Don't let it hang by the hose.

3

Loosen the front axle pinch bolt, using a ratchet and Allen driver. Insert a Phillips screwdriver shaft into the hole in the end of the front axle to hold the axle in place, and loosen the front axle nut.

4

Remove the front fender bolts and braces, using a ratchet, Allen driver and wrench. Pull the fender forward from between the front forks and remove it from the bike.

5

Place a bike jack under the frame pipes, just below the break between the engine case and the transmission, and lift the bike so that the rear tire clears the ground by an inch or so. Place the special jack, No. 57001-1238, under the engine case, and raise the jack until the rear tire touches the ground and the front tire clears the ground by an inch or so.

6

Finish removing the front axle nut, and pull the axle out through the right fork. Remove the front wheel from the forks. Inspect the front wheel hub seals, and replace them as necessary.

Installation

1

Apply a thin layer of bearing grease to the seal lip. Insert the front wheel spacers into the front wheel seals. Position the wheel between the front forks.

2

Insert the front axle through the right fork. Install the axle washer and nut. Insert a Phillips screwdriver shank into the hole in the axle, and torque the front axle nut to 79.7 foot-pounds using a foot-pound torque wrench and socket.

3

Position the front fender between the forks. Install the fender bolts and braces, using a ratchet, socket and wrench. Torque the front axle pinch bolt to 15 foot-pounds, using a foot-pound torque wrench and Allen driver.

4

Install the brake caliper over the brake disc. Gently spread the pads on the caliper slightly, using a flat screwdriver, if necessary, to get the caliper in position. Install and torque the caliper bolts to 25 foot-pounds, using a foot-pound torque wrench and socket.

5

Lower the bike and remove the jacks. Using the brake lever, pump up the front brake until you feel normal resistance, and test the operation of the front brake.

Warnings

  • close Suspend the brake caliper in such a way that there is no strain on the brake line or fittings. Letting the caliper hang by the hose can cause brake component damage.
  • close Always test the bike in a safe environment before entering traffic whenever you do brake or suspension work.
  • close Never lay a wheel assembly down on the brake-rotor side, or the rotor may become warped beyond the service limits. If you find it necessary to lay the wheel on the rotor side, always use wooden blocks to block the wheel up and support it without contacting, or bearing on, the rotor.

Items you will need

About the Author

TJ Hinton trained as an auto mechanic at Mississippi Gulf Coast Community College and then later graduated from MMI as a certified motorcycle mechanic . He's also worked for 20+ years in home construction, remodeling and repair. His articles appear on InternetAutoGuide.com and TopSpeed.com.