Special Tools
| Description | Part Number | Qty. |
|---|---|---|
| STEERING HEAD BEARING RACE INSTALLER | HD-39302 | 1 |
Consumables
| Description | Part Number | Size |
|---|---|---|
| SPECIAL PURPOSE GREASE | 99857-97A | 414 ml (14 fl oz) |
WARNINGProperly seat bearing cups in steering head bore. Improper seating can loosen fork stem bearings adversely affecting stability and handling, which could result in death or serious injury. (00302a)
WARNINGProperly adjust fork stem bearings. Improper adjustments can adversely affect stability and handling, which could result in death or serious injury. (00301c)
Steering Head Bearings
NOTICE
Replace both bearing assemblies even if one assembly appears to be good. Mismatched bearings can lead to excessive wear and premature replacement. (00532c)
| 1. | See Figure 1. If removed: Install new bearing cups (10) using bearing installer. Special Tool: STEERING HEAD BEARING RACE INSTALLER (HD-39302) | |
| 2. | Grease steering head bearings (9).SPECIAL PURPOSE GREASE (99857-97A) | |
| 3. | If removed: Install new dust shield (8) and new steering head bearing (9) on fork stem and lower fork bracket assembly (12). |
Lower Fork Bracket
| 1. | Install front fork stem and lower fork bracket assembly. a. Install fork stem through steering head (11). b. Install new upper steering head bearing (9) and new dust seal (8). | |
| 2. | Install upper fork bracket (5). |
Upper Fork Bracket
| 1. | If replacing upper fork bracket: a. Install fork lock. See Chassis → FORK LOCK. b. Install wireform (3) and screw (4). Tighten. Torque: 5–7 N·m (44–62 in-lbs) Wireform screw, brake line, front | |
| 2. | Install upper fork bracket assembly. a. Install washer (2) and fork stem screw (1). Tighten. Torque: 18–20 N·m (13–15 ft-lbs) Fork stem screw, 1st torque b. Loosen fork stem screw. Angle: 90° c. Final tighten fork stem screw. Torque: 11.5–12.5 N·m (102–111 in-lbs) Fork stem screw, final torque | |
| 3. | Tighten fork stem pinch screw (7). Torque: 20–24 N·m (15–18 ft-lbs) Fork stem pinch screw |
| 1 | Fork stem screw |
| 2 | Washer |
| 3 | Wireform |
| 4 | Screw |
| 5 | Upper fork bracket |
| 6 | Upper fork bracket pinch screw (2) |
| 7 | Fork stem pinch screw |
| 8 | Dust seal (2) |
| 9 | Steering head bearing (2) |
| 10 | Bearing cup (2) |
| 11 | Steering head |
| 12 | Fork stem and lower fork bracket assembly |
| 13 | Lower fork bracket pinch screw (4) |
Figure 1. Fork Stem and Bracket Assembly