Steering stem removal
Remove the front wheel (see Front wheel removal in the Wheels/Tires chapter).
Caution! Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. The motorcycle could be damaged.
Warning! Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. It could cause an accident and injury.
Remove:
- Headlight Unit (see Headlight body removal in the Electrical System chapter)
- Turn Signal Light Lead Connectors [A]
- Turn Signal Lead Bracket Bolts [B]
- Turn Signal Bracket Bolts (Left and Right) [C]
- Brake Hose [D] (from the clamp)
- Turn Signal (with the Bracket)
- Front Turn Signal Light
![](https://motoinstruction.ru/img/kawasaki/13/119363.jpg)
Remove:
- Headlight Body Bracket Nuts [A]
- Headlight Body (with the Bracket)
![](https://motoinstruction.ru/img/kawasaki/13/119364.jpg)
Remove:
- Handlebar Holder Nuts [A]
- Clamp [B]
- Handlebar Holders with the Handlebar installed [C]
- Upper Front Fork Clamp Bolts [D] (Left and Right)
![](https://motoinstruction.ru/img/kawasaki/13/119365.jpg)
Remove:
- Steering Stem Head Nut [A] and Washer
- Front Forks (see Front Fork Removal (each fork leg) in the Suspension chapter)
- Steering Stem Head [B]
![](https://motoinstruction.ru/img/kawasaki/13/119366.jpg)
Bend the claws [A] of the claw washer straighten.
Remove:
- Steering Stem Locknut [B]
- Claw Washer
![](https://motoinstruction.ru/img/kawasaki/13/119367.jpg)
Remove: Steering Stem Nut [A].
- Special Tool - Steering Stem Nut Wrench [B]: 57001-1100
Remove: Stem Cap [C].
Pull out the steering stem [D] from the bottom.
Remove the plug at steering stem bottom.
![](https://motoinstruction.ru/img/kawasaki/13/119368.jpg)
Steering stem installation
Apply grease to the needle bearings.
Install:
- Steering Stem [A]
- Bearing [B]
- Stem Cap [C]
- Stem Nut [D]
- Plug [E]
![](https://motoinstruction.ru/img/kawasaki/13/119369.jpg)
Settle the bearings in place as follows:
Tighten the stem nut to 55 N·m (5.6 kgf·m, 40 ft·lb) of torque (To tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 N (31.1 kgf, 68.6 lb) force in the direction shown.).
- Special Tool - Steering Stem Nut Wrench [A]: 57001-1100
![](https://motoinstruction.ru/img/kawasaki/13/119370.jpg)
Force [B]
Loosen the stem nut.
Retighten the stem nut to the specified torque.
- Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
For the torque of 4.9 N·m (0.50 kgf·m, 43 in·lb), pull the wrench at the hole by 27 N (2.8 kgf, 6.1 lb) force.
Replace the claw washer [A] with a new one.
Install the claw washer 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 front forks (see Front fork installation in the Suspension chapter).
Install the stem head.
Install the washer [F], and tighten the stem head nut [G] with specified torque.
![](https://motoinstruction.ru/img/kawasaki/13/119371.jpg)
Note. Tighten the upper fork clamp bolts first, next the stem head nut, last the lower fork clamp bolts.
Torque:
- Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
- Steering Stem Head Nut: 49 N·m (5.0 kgf·m, 36 ft·lb)
- Lower Front Fork Clamp Bolts: 34 N·m (3.5 kgf·m, 25 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.
- Check and adjust the following items after installation. Steering (see Steering play inspection in the Periodic Maintenance chapter)
- Throttle Cables (see Throttle control system inspection in the Periodic Maintenance chapter)
- Headlight Aim (see Headlight aiming inspection in the Periodic Maintenance chapter)
Check the front brake effectiveness.
Warning! Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.
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/13/119372.jpg)