STEERING STEM
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BOLTS/COLLARS |
Remove the following:
- Front visor ('05 - '07: page 3-5, After '07: page 36)
- Handlebar (page 14-32)
- Front wheel (page 14-8)
After '07: Remove the steering damper (page 14-38).
Remove the bolts, collars and front fender.
FRONT FENDER
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BOLTS/BRAKE HOSE GUIDES |
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'05 - '07 shown!^^^^ BOU7TRIPMETER CABLE GUIDE |
Remove the bolts and brake hose guides. Remove the bolt and tripmeter cable guide.
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'05-'07: TRIPMETER |
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trTpmeter^ Ці GUIDE |
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NUTS/WASHERS |
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OS - '07: Remove the nuts, washers, tripmeter and connector stay.
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NUTS |
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BOLT |
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After '07: |
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After '07. Remove the nuts, cable guide and tripmeter. Remove the bolt and connector stay.
Remove the steering stem nut and washer. Remove the forks (page 14-13).
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NUT/WASHER |
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STEERING STEM SOCKET |
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ADJUSTING NUT |
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Remove the fork top bridge.
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TOP BRIDGE |
Remove the steering stem adjusting nut using the special tool.
TOOL:
Steering stem socket 07916-3710101 or
07702-0020001 (U. S.A. only)
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UPPER BEARING |
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STEERING STEM |
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'05-'07 shown: DUST SEAL |
Remove the upper dust seal, upper tapered roller bearing and steering stem.
Check the bearings and outer races for wear or damage.
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Always replace the bearings and races as a set. |
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BALL RACE REMOVER
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Remove the upper and lower bearing outer races from the head pipe using the special tools.
TOOL:
Ball race remover 07946-3710500
Install a new lower outer race, bearing race installers and installer shaft as shown.
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INSTALLER SHAFT |
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BEARING RACE INSTALLERS |
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LOWER OUTER RACE |
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Hold the shaft with a wrench and turn the installer to install the lower outer race.
TOOLS:
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07VMF-K230100 07VMF-KZ30200 |
Bearing race installer (2 required)
Installer shaft
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INSTALLER SHAFT UPPER OUTER RACE
BEARING RACE INSTALLERS |
Install a new upper outer race, bearing race installers and installer shaft as shown.
Hold the shaft with a wrench and turn the installer to install the upper outer race.
TOOLS:
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07VMF-KZ30100 07VMF-KZ30200 |
Bearing race installer (2 required)
Installer shaft
Temporarily install the stem nut to avoid damaging the steering stem threads.
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'05 - '07 shown: STEERING STEM |
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LOWER BEARING |
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DUST SEAL |
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LOWER |
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STEM NUT ■ca^ DUST SEAL |
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Remove the lower tapered roller bearing and dust seal from the steering stem.
Apply urea based multi-purpose grease with extreme pressure to the dust seal lips.
Install a new dust seal.
Install the lower bearing using a hydraulic press and the special tool as shown.
TOOL:
Attachment, 30 mm I. D. 07746-0030300
NOTE:
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'05 - '07 shown: DUST SEAL UPPER BEARING |
• Use water resistant grease #2 (urea based multipurpose grease) for the steering bearings and dust seals:
- Excelite EP2 (Kyodo Yushi)
- Stamina EP2 (Shell) or equivalent
Pack the upper and lower tapered roller bearings with grease.
Apply grease to all of the bearing surfaces.
Install the upper tapered roller bearing in the steering head.
Slide the steering stem into the steering head from the bottom.
Install the upper dust seal.
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STEERING STEM SOCKET
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'05 - '07 shown: TOP BRIDGE |
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NUT/WASHER |
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'05 - '07: |
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‘05 - ‘07: |
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TRIPMETER |
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tripmetefP Ц GUIDE |
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NUTS/WASHERS After '07: |
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BOLT |
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NUTS |
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After '07: |
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Install the steering stem adjusting nut. Tighten the steering stem adjusting nut to the specified torque using the special tool. TORQUE: 30 N m (3.1 kgf m, 22 lbf-ft) TOOL: Steering stem socket 07916-3710101 or 07702-0020001 (U. S.A. only) Move the steering stem lock-to-lock several times to seat the bearings. Loosen the adjusting nut to torque of 0 N-m (0 kgf-m, 0 lbf-ft), and retighten to the specified torque. TORQUE: 7.0 Nm (0.7 kgf m, 5.2 Ibf ft) Recheck that the steering stem moves smoothly without play or binding. Install the top bridge and washer. Loosely install the stem nut. Insert the forks (page 14-30). Tighten the stem nut to the specified torque. TORQUE: 108 N-m (11.0 kgf-m, 80 Ibf ft) Recheck the steering stem adjustment by turning the top bridge lock-to-lock and checking for smoothness. There should be no binding. |
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Install the tripmeter, cable guide, nuts and tighten the nuts securely. Install the connector stay, bolt and tighten the bolt securely. |
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Install the connector stay, tripmeter, washers and tighten the nuts securely. |
Install the tripmeter cable guide and tighten the bolt securely.
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khown-ЩІ jr"", 4PMETER CABLE GUIDE |
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Install the front brake hose guides and tighten the bolts to the specified torque.
TORQUE: 5.2 N m (0.5 kgf m, 3.8 Ibf ft)
Install the front fender, collars and tighten the bolts securely.
After '07: Install the steering damper (page 14-38).
Install the following:
- Front wheel (page 14-12)
- Handlebar (page 14-34)
- Front visor ('05 - '07: page 3-5, After '07: page 36)
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CLUTCH LEVER PIVOT BOLT |
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CLUTCH LEVER |
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Remove the clutch lever pivot nut, bolt, collar, clutch lever and hot start lever.
Apply grease to the sliding surface of the clutch lever pivot bolt.
Install the clutch lever, hot start lever, collar, clutch lever pivot bolt and nut.
Tighten the pivot bolt to the specified torque. Loosen the pivot bolt to 45° - 90°, and tighten the pivot nut to the specified torque.
TORQUE:
Clutch lever pivot bolt:
2.0 N m (0.2 kgf m, 1.5 Ibf ft) - 45° to 90 Clutch lever pivot nut:
10 N m (1.0 kgf m, 7 Ibf ft)
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SHOCK LINKAGE |
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15-30 |
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COMPONENT LOCATION........................ 15-2 |
