Kawasaki Ninja Service Manual: Stem, Stem Bearing Installation

• Replace the bearing outer races with new ones.
• Drive them into the head pipe at the same time.

Special Tools - Head Pipe Outer Race Press Shaft [A]: 57001-1075

Head Pipe Outer Race Driver,
55 [B]: 57001 -1446 or Bearing Driver Set: 57001-1129

• Apply grease to the outer races.

• Replace the bearing inner races and oil seal with new ones.
• Apply grease to the oil seal.
• Install the oil seal [A] on the steering stem, and drive the lower ball bearing inner race [B] applied the grease onto the stem.

Special Tools - Steering Stem Bearing Driver, 42.5 [C]:
57001-1344

Steering Stem Bearing Driver Adapter,
41.5 [D]: 57001-1345

• Apply grease to the lower ball bearing [A], and install it onto the steering stem.

The lower and upper ball bearings are identical.

• Apply grease to the upper ball bearing [B] and inner race [C].
• Install the steering stem [A] through the head pipe and install the upper bearing [B] and inner race [C] on it.
• Install: Stem Cap [D] Steering Stem Nut [E]

• Settle the bearings in place as follows

Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A].

Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)

• Install the claw washer [A] 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 stem head.
• Install the washer, and temporary tighten the stem head nut.
• Install the front forks (see Front Fork Installation in the Suspension chapter).

NOTE

• Tighten the front fork clamp bolts (upper) first, next the stem head nut, last the front fork clamp bolts (lower).
• Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque.

Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, 17 ft·lb) Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Install the removed parts (see appropriate chapters).

Steering Stem Bearing Lubrication

• Refer to the Steering Stem Bearing Lubrication in the Periodic Maintenance chapter.