Like this Manual?SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Inspection
Move the handle bar right-to-left. The steering should move smoothly. If the steering is rough the bearing seals may need to be lubricated. Check for any cables, wires, and hoses that may be binding. Other causes of steering roughness could be a bent steering shaft, problems with the tie-rods, or steering knuckles.
See the following topics for more information.
Removal
Remove the front fender. See the Front Fender topic for more information.
Remove the inner covers. See the Inner Covers topic for more information.
Remove the inner tie rod ends. See the Tie-Rods topic for more information.
Remove the handlebars. See the Handlebar topic for more information.
Loosen the two steering stem bearing housing bolts with a 12 mm socket.
Remove the two steering stem bearing housing bolts from the front differential.
Remove the two steering stem clamp bolts with a 5 mm Allen.
Remove the collars.
Remove the steering stem clamp.
Remove the steering stem. Inspect the bearing, ball joint halves (700 and 2002 – 2003 650 models), and grease seals. Replace the parts as needed.
Remove the cotter pin from the steering stem nut.
Remove the steering stem nut with a17 mm socket.
Remove the steering stem bearing housing from the steering stem shaft.
Remove the collar/s. The 2005 and newer models only have one collar on the bottom. The 700 and 2002 – 2003 650 models have a collar on each side of the bearing housing.
Inspect the steering stem bearing housing grease seals and bearing. Replace the components as set if needed.
Installation
Pack the grease seal cavities with grease. Install the collar/s. The 2005 and newer models only have one collar on the bottom. The 700 and 2002 – 2003 650 models have a collar on each side of the bearing housing. Fit the steering stem into the steering stem bearing housing.
Install the steering stem nut. Tighten the nut to specification.
Steering Stem Bottom End Nut: 64 N-m, 6.5 kgf-m, 47 ft-lb
Install a new cotter pin and bend it securely.
Lubricate the steering stem bearing and coat the grease seal lips with grease.
Install the ball joint halves (700 and 2002 – 2003 650 models) to the steering stem.
Apply grease to the inside of the steering stem clamp where it will contact the steering stem.
Install the collars and the steering stem clamp to the frame.
Install the steering stem clamp bolts and tighten them to specification with a 5 mm Allen.
Steering Stem Clamp Bolts: 25 N-m, 2.5 kgf-m, 18 ft-lb
Apply a non-permanent thread locking agent to the threads of the steering stem bearing housing bolts. Install the two steering stem bearing housing bolts to the front differential. Tighten the bolts securely with a 12 mm socket.
Install the handlebars. See the Handlebar topic for more information.
Install the inner tie rod ends. See the Tie-Rods topic for more information.
Install the front fender. See the Front Fender topic for more information.
Check the toe-in. See the Toe-In Adjustment topic for more information.