Stem, Stem Bearing Removal
Remove:
- Middle Fairings (See Middle Fairing Removal in the Frame chapter)
- Inner Cover (See Inner Cover Removal in the Frame chapter)
- Bolt [A]
- Clamp [B]
![](https://motoinstruction.ru/img/kawasaki/23/129010.jpg)
Remove:
- Bolt [A] Clamp [B]
![](https://motoinstruction.ru/img/kawasaki/23/129011.jpg)
Remove:
- Bolt [A]
- Brake Hose Clamp Bracket [B]
![](https://motoinstruction.ru/img/kawasaki/23/129012.jpg)
- Remove the handlebar and lower handlebar holder (See Handlebar Removal).
- Loosen the steering stem head bolt [A].
Remove:
- Front Wheel (See Front Wheel Removal in the Wheels/Tires chapter)
- Steering Stem Head Bolt and Washer [B]
- Loosen the front fork clamp bolts (upper) [C], and remove the steering stem head [D].
![](https://motoinstruction.ru/img/kawasaki/23/129013.jpg)
- Remove the front forks (See Front fork) Removal in the Suspension chapter).
- Bend the claws [A] of the claw washer straighten.
Remove:
- Steering Stem Locknut [B]
- Claw Washer [C]
![](https://motoinstruction.ru/img/kawasaki/23/129014.jpg)
- Pushing up the stem base, and remove the steering stem nut [A] with stem cap [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
- Remove the steering stem [D] under side.
![](https://motoinstruction.ru/img/kawasaki/23/129015.jpg)
- Remove the upper stem bearing inner race [A] and bearing [B].
![](https://motoinstruction.ru/img/kawasaki/23/129016.jpg)
- To remove the bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head pipe, and applying it to both recess alternately hammer it to drive the race out.
Note: If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
![](https://motoinstruction.ru/img/kawasaki/23/129017.jpg)
- Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable commercially available chisel [B].
![](https://motoinstruction.ru/img/kawasaki/23/129018.jpg)
Stem, Stem Bearing Installation
- Replace the bearing outer races with new ones.
- Apply grease to the outer races, and drive them into the head pipe at the same time.
Special Tool - Bearing Driver Set [A]: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/129019.jpg)
- Replace the bearing inner races and oil seal with new ones.
- Apply grease to the oil seal.
- Drive the lower ball bearing inner race applied the grease onto the stem.
Special Tools-Steering Stem Bearing Driver, ∅42.5 [A]: 57001-1344
Steering Stem Bearing Driver Adapter, ∅41.5 [B]: 57001-1345
![](https://motoinstruction.ru/img/kawasaki/23/129020.jpg)
- Apply grease to the lower ball bearing [A], and install it onto the stem.
- Apply grease to the upper ball bearing [B] and inner race [C].
![](https://motoinstruction.ru/img/kawasaki/23/129021.jpg)
- Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it.
- Install the stem cap [D] and steering stem nut [E].
![](https://motoinstruction.ru/img/kawasaki/23/129022.jpg)
- Settle the inner races in place as follows.
Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 fbib) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a stem nut wrench [A] in the direction shown.
Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 20 Nm (2.0 kgf·m, 15 ftib)
![](https://motoinstruction.ru/img/kawasaki/23/129023.jpg)
- Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C].
- Hand tighten the stem locknut until it touches the claw washer.
- Tighten the stem locknut clockwise until the claws are aligned with the grooves (ranging from 2nd to 4th) of stem nut [D], and bend the 2 claws downward [E].
- Install the stem head.
- Install the washer, and tighten the stem head bolt with specified torque.
- Install the front forks (See Front Fork Installation in the Suspension chapter).
![](https://motoinstruction.ru/img/kawasaki/23/129024.jpg)
Note: Tighten the upper fork clamp bolts first, next the stem head bolt, last the lower fork clamp bolts. Tighten the two lower fork clamp bolts alternately two times to ensure even tightening torque.
Torque - Front Fork Clamp Bolts (Upper): 20 Nm (2.0 kgf·m 15 ft·lb)
Steering Stem Head Bolt: 108 Nm (11.0 kgf·m, 80 ft·lb)
Front Fork Clamp Bolts (Lower): 29 Nm (3.0 kgf·m 21 ft·lb)
Warning: Do not impede the handlebar turning by routing the cables, harnesses and hoses improperly (See Cable, Wire, and Hose Routing section in the Appendix chapter).
- Install the removed parts (see appropriate chapters).
Stem Bearing Lubrication
- Refer to the Steering Stem Bearing Lubrication in the Periodic Maintenance chapter.
Steering Stem Warp
- Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
![](https://motoinstruction.ru/img/kawasaki/23/129025.jpg)
Stem Cap Deterioration, Damage
Replace the stem cap if its oil seal [A] shows damage.
![](https://motoinstruction.ru/img/kawasaki/23/129026.jpg)