Kawasaki Ninja Service Manual: Stem, Stem Bearing Installation

Kawasaki Ninja Service Manual / Steering / Steering Stem / 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

Stem, Stem Bearing Installation

Apply grease to the outer races.

Stem, Stem Bearing Installation

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

Stem, Stem Bearing Installation

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]

Stem, Stem Bearing Installation

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)

Stem, Stem Bearing Installation

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].

Stem, Stem Bearing Installation

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)

WARNING

If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death.

Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Install the removed parts (see appropriate chapters).

Steering Stem Bearing Lubrication

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

Stem, Stem Bearing Removal

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal ...

Steering Stem Warp Inspection

Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steer ...

Other materials:

Torque Limiter Installation
Apply molybdenum disulfide grease to the torque limiter shaft [A]. Install the torque limiter [B], the collar [C] and the shaft. Turn the large-hole end of the shaft to inside as shown in the figure. Replace the washer [D] with a new one. Apply a non-permanent locking agent to the t ...

Armature Inspection
Using the × 1 Ω hand tester range, measure the resistance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. ...

Steering Stem Bearing Lubrication
Remove the steering stem (see Stem, Stem Bearing Removal in the Steering chapter). Using a high flash-point solvent, wash the upper and lower ball bearings [A] in the cages. Wipe the upper and lower outer races which are press -fitted into the head pipe to clean off grease and dirt. V ...