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
| 1. | See Figure 1. Install steering head (12). | |
| 2. | Install screws (11). Tighten. Torque: 40–44 N·m (30–32 ft-lbs) Steering head screws | |
| 3. | Position brake line and install screw (6). Tighten. Torque: 5–7 N·m (44–62 in-lbs) Brake line retainer screw | |
| 4. | If replacing steering head: a. Install fork lock. See Chassis → FORK LOCK. b. Install bearing races. See Steering Head Bearings in this section. | |
| 5. | Install upper and lower fork brackets. See Upper Fork Bracket and Lower Fork Bracket in this section. | |
| 6. | Connect fork lock connector. See Chassis → FORK LOCK. |
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 (9) using bearing installer. Special Tool: STEERING HEAD BEARING RACE INSTALLER (HD-39302) | |
| 2. | Grease steering head bearings (7).SPECIAL PURPOSE GREASE (99857-97A) | |
| 3. | If removed: Install new dust shield (5) and new steering head bearing (7) on fork stem and lower fork bracket assembly (10). |
Lower Fork Bracket
| 1. | See Figure 1. Install front fork stem and lower fork bracket assembly (10). a. Install fork stem through steering head (12). b. Install new upper steering head bearing (7) and new dust seal (5). | |
| 2. | Install upper fork bracket. See Upper Fork Bracket in this section. |
Upper Fork Bracket
| 1. | See Figure 1. Install upper fork bracket assembly (1). a. Install washer (3) and steer stem screw (4). Tighten. Torque: 18–20 N·m (13–15 ft-lbs) Steer stem screw, 1st torque b. Loosen steer stem screw. Angle: 90° c. Final tighten steer stem screw. Torque: 11.5–12.5 N·m (102–111 in-lbs) Steer stem screw, final torque | |
| 2. | Tighten steer stem pinch screw (4). Torque: 20.4–25 N·m (15–18 ft-lbs) Steer stem pinch screw |
| 1 | Upper fork bracket |
| 2 | Steer stem screw |
| 3 | Washer |
| 4 | Steer stem pinch screw |
| 5 | Dust seal (2) |
| 6 | Screw |
| 7 | Steering head bearing (2) |
| 8 | Lower fork bracket pinch screw (4) |
| 9 | Bearing cup (2) |
| 10 | Fork stem and lower fork bracket assembly |
| 11 | Steering head screws (4) |
| 12 | Steering head |
| 13 | Upper fork bracket pinch screw (2) |
Figure 1. Fork Stem and Bracket Assembly