Installation

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Drive in the new outer steering head bearing races with a suitable bearing race driver or Steering bearing installer tool.

Special Tool- Steering Outer Race Installer: 09941-34513

Drive the lower bearing onto the steering stem with a steering bearing installer tool.

Special Tool- Steering Bearing Installer: 09941-74910

Apply a liberal amount of wheel bearing grease to all bearings.

Install the upper inner bearings . Install the upper tapered bearing on the 2003 and newer models.

Install the steering stem into the steering head.

Coat the lips of the dust seal in grease and place it over the steering stem. Thread on the steering adjusting nut.

Tighten the steering stem adjusting nut to the specification with a pin spanner or steering stem nut wrench.

Special Tools -

(600) Steering Stem nut wrench: 09940-14910

(750) Steering Stem nut wrench: 09940-1491

(Steering Stem Nut Torque: 40 - 50 N-m or 29 - 36 lb-ft)

Turn the lower fork clamp lock to lock five or six time so that the bearings seat properly.

Loosen the steering stem adjusting nut 1/4 to 1/2 turn.

Install the horn. Plug in the two horn connectors and insert the two horn bracket mounting bolts. Tighten the bolts securely with a 10 mm socket.

Install the brake hose joint bolt and tighten its securely with a 10 mm socket.

Place the upper fork clamp onto the steering stem. Install the steering stem washer and cap nut onto the steering stem. Wait until the forks are installed to torque the steering cap nut to specification with a 22 mm socket.

(Steering Stem Nut Torque: 35 - 55 N-m or 25.5 - 40.0 lb-ft)

Install the forks. See the Fork Removal and Installation topic for more information.

Plug in the ignition switch connector.

Note: If you are viewing this document offline be sure to visit the latest version online at http://www.cyclepedia.com before attempting any repairs. Updates are made without notice.