Ktm 950 SMR Installation and Removal Manual

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Filed Under (KTM) by admin on 27-01-2012

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Be sure the triple clamp in your kit has a part # 3012R- 27 -6-0208 on the bottom side. This is very important. 2. Warning: Once the triple clamp is loose, the forks can roll away from the bike . Block it up properly to start with. 3. Block the front tire securely before removing the top triple clamp, so the tire cannot move forward. It’s best to tie the forks up to something above you, like the rafters, using tie downs, or a tie down from the front axle up and over the frame backbone and then underneath the lower triple clamp. Once the forks start to come off while working, it’s extremely difficult to get them back together without help. Block the back wheel up also, so it puts pressure on the front end, forcing it to stay in position. Spend the time setting this up correctly and your installation will go easier. 4. This kit requires removal of the headless “Security” bolts that hold the key switch in place. These bolts will need to be drilled out in order to remove them, pictures below. Removal is fairly easy, if you follow these instructions. 5. Examine all the wire and cable routing before removal and make notes of where everything goes. 6. Remove 2 bolts that hold the headlight shroud in place. Be careful not to lose the small bushings that fall out easily. 7. Follow the wire from the ignition switch to the wire loom in the headlight shroud and unplug it. There is no locking tab on this plug so you can usually undo it without having to disassemble the wiring. 8. Remove the 4 bolts that hold your bars tight and lay the bars forward out of the way (Bungie or tie to the front of bike). 9. Be sure the front end is securely blocked or tied to something above the bike. Remove the top triple clamp, taking note of how tight the 27mm main nut is, so you can re-tighten to the exact tension for the bearing. The main nut merely provides the correct tension on the head tube bearing, so the tension is critical. The nut will NOT be tight coming off. Once the fork and triple clamp pinch bolts are loose, the main nut can be removed. It’s difficult to get a wrench on the main nut. We were able to sneak the stock KTM axle wrench in there, otherwise, you may have to loosen the lower bar perches using an 8mm Allen wrench and a 17mm socket for the underside nuts. Once the main nut is off, lift the triple clamp off carefully , trying not to disturb the blocked-front-wheel. A rubber mallot is helpful here

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