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Discussion Starter #1
Hello all.

Traded my beloved KTM Duke II for 2004 a 749 Dark with Termi, Sargent seat, CF hugger, covers, shield. Nice...After getting over the fact that it feels gutless compare to my R1 (just sold it), I must make some mods :rolleyes: .

I have a set of Heli's, vortex bar-ends and a 520 kit with 14/43 on the way. I am waiting for the service manual coming on CD this August. In the meantime can you guy tell me the torque for the sprocket bolts and the rear axle nut? Do you guy have a special tool for the chain adjuster or just use metal rod? Same for the head bearing?

lastly the torque for the top clamp after I install the bars?

I just came back from downtown Boston on Friday rush traffic and the stock sprocket ratio is EVIL :mad:

I am still glad I got the 749 as it is neat to rev the piss out it. Loundon here I come :p
 

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sprocket bolt torque: 46 Nm
rear axle nut: 180 Nm
front axle nut: 63 Nm (VERY IMPORTANT not to go more, I've stripped one)

Yes, just use 2 small rods, I use a screwdriver and a small L-shaped allen key.

Can you be more specific on the tripple clamp?
 

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Discussion Starter #3
Just the pinch bolts on the top clamp (one on each side) since I have to take it off to put hte new bars.

Thanks for the reply! :)
 

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You mean 3, one on each fork leg, and one on the center steering post.
The manual has 2 listings for the pinch bolts, I can't find where it differentiates between the two. Either way, it's either 23 Nm or 22 Nm, depending on which one (it also calls for +/- 5% on each).
Also, grease them with SHELL Retinax HDX2. I found that MOTOREX MOLY 218, RENOLIT LZR 2, and RENOLIT FG 150 are compatible (They are fifth-wheel greases). If you can't find any of those, you should be able to find something else that is a "long-term high pressure lubricant (NLGI Class 2) with MoS2 or graphite additives". Or, do like me and use whatever grease you have laying around the garage.
 

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Discussion Starter #5
Thanks again man, I appreciate you looking it up. :)
 

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Discussion Starter #6
Alright I am brain dead. I am doing the job right now and I forgot to ask the torque for the front sprocket....I am all done and dying to go try the mod.

anyone?

Gerard
 

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snellen said:
Alright I am brain dead. I am doing the job right now and I forgot to ask the torque for the front sprocket....I am all done and dying to go try the mod.

anyone?

Gerard
I would imagine it's the same as on my 749S... 186Nm + the grease mentioned above.
 
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