Warning!
- Make sure the motorcycle is stabilised and adequately supported.
- A correctly supported motorcycle will help prevent it from falling.
- An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
1. Raise and support the front of the motorcycle.
2. Release the fixings securing the handlebar clamps to the risers, detach the clamps and release the handlebar.
3. As an assembly, raise the handle bars until clear of the upper yoke. Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
4. Loosen the upper yoke pinch bolts.
Warning! If the lower yoke fixings are also loosened, the forks will no longer support the weight of the motorcycle. Do not loosen the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.
Caution! Care must be taken when removing the upper yoke centre nut, to ensure that the centre nut and upper yoke do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching.
5. Remove the upper yoke centre nut from the steering stem.
1. Upper yoke centre nut
6. Ease the upper yoke from the forks and support while detached.
Note: When adjusting the bearing free play, ensure that the threaded part of the stem is free from grease.
7. Adjust the bearing free play as follows, all using T3880023 - 50 mm Socket:
- Remove the lock nut and tab washer. Discard the washer.
- Thoroughly clean the threads on the steering stem.
- Loosen the adjuster nut then tighten to 40 Nm.
- Loosen the adjuster nut, then retighten to 10 Nm.
- Fit a new tab washer and the lock nut.
Warning! It is essential that the adjuster nut is not over-tightened. If the adjuster nut is over-tightened it will cause a pre-load on the headstock bearings. This will introduce tight steering, which could cause loss of control and an accident.
- Hold the adjuster nut in position while tightening the lock nut to 40 Nm.
1. Adjuster nut; 2. Lock nut; 3. T3880023 - 50 mm Socket
8. Refit the upper yoke assembly to the forks.
9. Fit the upper yoke centre nut and tighten to 90 Nm.
10. Tighten the upper yoke pinch bolts to 26 Nm.
11. Locate the handlebar assembly in the lower halves of the clamps. Fit the upper clamps and bolts.
12. Align the handlebar alignment mark with the front split line of the right hand riser.
13. Tighten the front clamp bolts to 26 Nm, then the rears.
1. Right hand split line; 2. Alignment mark
14. Recheck the bearing adjustment (see Steering head bearing - check).