Prepare
1. Remove headlamp fairing. See Headlamp fairing.
2. Remove front brake line clamp from lower fork bracket. See Brake lines.
3. Remove front fork tubes. See Front fork.
Remove
1. See Figure 3-40. Remove front fork stem and lower fork bracket assembly.
- a. Support upper fork bracket (2).
- b. Remove fork stem pinch screw (9).
- c. Remove fork stem screw (4) and washer (3).
- d. Remove fork stem and lower fork bracket assembly (1) from steering head (7).
2. Remove lower steering head bearing (6) from fork stem and lower fork bracket assembly.
3. Remove upper steering head bearing.
4. Discard dust seals (5).
Install
| FASTENER | TORQUE VALUE | |
| Fork stem screw, first torque | 22.6 Nm | 200in·lbs |
| Fork stem screw, second torque | 8.5 Nm | 75in·lbs |
| Fork stem pinch screw | 50.0-60.0 Nm | 37-44 ft·lbs |
Warning: Properly 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.
Warning: Properly adjust fork stem bearings. Im proper adjustments can adversely affect stability and handling, which could result in death or serious injury.
1. See Figure 3-40. Install front fork stem and fork bracket assembly.
- a. Install new dust seal (5) and lower steering head bearing (6) over fork stem and lower fork bracket assembly (1).
- b. Install fork stem through steering head (7).
- c. Install upper steering head bearing and new dust seal.
- d. Align upper fork bracket (2) with fork stem.
- e. Install washer (3) and fork stem screw (4). Tighten fork stem screw to 22.6 Nm (200in·lbs).
- f. Loosen fork stem screw 90 degrees. Tighten to 8.5 Nm (75in·lbs).
- g. Tighten fork stem pinch screw to 50.0-60.0 Nm (37-44 ft·lbs).
Figure 3-40. Fork Stem and Bracket Assembly: 1. Fork stem and lower fork bracket assembly; 2. Upper fork bracket; 3. Washer; 4. Fork stem screw; 5. Dust seal (2); 6. Steering head bearing (2); 7. Steering head; 8. Bearing cup (2); 9. Fork stem pinch screw
Clean and inspect
| PART NUMBER | TOOL NAME |
| HD-33416 | UNIVERSAL DRIVER HANDLE |
| HD-39301-A | STEERING HEAD BEARING RACE REMOVAL TOOL |
1. Clean all parts.
2. Inspect fork stem and upper and lower brackets. Replace as necessary.
Notice: Replace both bearing assemblies even if one assembly appears to be good. Mismatched bearings can lead to excessive wear and premature replacement.
3. Inspect bearings for the conditions below. Replace as necessary.
- Pitting
- Wear
- Scoring
4. Inspect bearing cups. Replace as necessary
- a. Drive bearing cups from steering head using STEERING HEAD BEARING RACE REMOVAL TOOL (Part # HD-39301-A) and UNIVERSAL DRIVER HANDLE (Part # HD-33416).
- b. Install new steering head bearing cups.
Complete
1. Install front fork tubes. See Front fork.
2. Install front brake line clamp to lower fork bracket. See Brake lines.
3. Check front fork fall away. See Adjust steering head bearings.
4. Install headlamp fairing. See Headlamp fairing.