Steering

9.6 Drawbolt arrangement for fitting steering stem bearing races

1 Long bolt or threaded bar

2 Thick washer

3 Guide for lower race

6 Press the new races into the head using a drawbolt arrangement (see illustration), or by using a large diameter tubular drift. Ensure that the drawbolt washer or drift (as applicable) bears only on the outer edge of the race and does not contact the working surface. Alternatively, have the races installed by a Kawasaki dealer equipped with the bearing race installing tools.

7 To remove the lower bearing from the steering stem, clamp the stem in a vice and use two flat-bladed screwdrivers placed on opposite sides of the race to work it free, using blocks of wood to protect the yoke (see illustration). If the bearing is firmly in place it will be necessary to use a bearing puller, or in extreme circumstances to split the bearing's inner section (see illustration).

9.8 Drive the new bearing on using a suitable bearing driver or a length of pipe that bears only against the inner race and not against the rollers or cage

9.7b ... or remove it using a bearing puller second shock is removed, but also making sure that the weight of the machine is off the rear suspension so that the shocks are not compressed. Alternatively, remove only one shock at a time.

2 On 550 models, remove the exhaust system, and on 750 models, remove the silencer on the side which the shock is being removed from (remove both silencers if both shocks are being removed) (see Chapter 3).

3 Remove the shock absorber lower mounting bolt. The right-hand shock absorber bolt threads into a nut, whilst the left-hand shock bolt threads into the chain guard bracket (see illustrations). When removing the right-hand shock, counter-hold the bolt and unscrew the nut. Swing the shock rearwards until the bottom clears the mounting bracket on the swingarm.

4 Supporting the shock absorber, unscrew and remove the upper mounting bolt and washer, then remove the shock (see illustrations).

10.3b Left-hand shock absorber lower mounting

10.4b ... and remove the shock absorber

Removal

9.7a Remove the lower bearing as shown ...

8 Fit the new lower bearing onto the steering stem. A length of tubing with an internal diameter slightly larger than the steering stem will be needed to tap the new bearing into position (see illustration). Ensure that the drift bears only on the inner edge of the bearing and does not contact the rollers, or better still fit a washer between the bearing and the tubing to protect the bearing.

9 Install the steering stem (see Section 8).

10.3a Right-hand shock absorber lower mounting

10.4a Unscrew the upper mounting bolt...

1 Place the machine on its centre stand or support It upright using an auxiliary stand. If both shock absorbers are to be removed at the same time, position a support under the rear wheel so that it does not drop when the

10.3a Right-hand shock absorber lower mounting

1 Place the machine on its centre stand or support It upright using an auxiliary stand. If both shock absorbers are to be removed at the same time, position a support under the rear wheel so that it does not drop when the

11.1a Spring pre-load adjuster -550 models

11.1b Spring pre-load adjuster-750 models

10.10 Make sure the chain guard bracket is correctly aligned

10.6 Inspect the damper rod (arrowed) for pitting and leakage ...

10.7 ... and the bushes for wear and deterioration

10.6 Inspect the damper rod (arrowed) for pitting and leakage ...

10.7 ... and the bushes for wear and deterioration

11.1a Spring pre-load adjuster -550 models

11.1b Spring pre-load adjuster-750 models

10.10 Make sure the chain guard bracket is correctly aligned

Inspection

5 Inspect the shock absorber for obvious physical damage and the coil spring for looseness, cracks or signs of fatigue.

6 Inspect the damper rod for signs of bending, pitting and oil leakage (see illustration).

7 Inspect the pivot hardware at the top and bottom of the shock for wear or damage (see illustration).

8 If the shock absorber is in any way damaged or worn it must be replaced. Individual replacement components are not available.

9 Kawasaki specify releasing the nitrogen gas pressure before discarding the shock absorber. To do this, remove the cap from the base of the reservoir, then, using a screwdriver or other suitable tool, depress the valve until all the nitrogen is released. If in doubt, take the shocks to a dealer for disposal.

A Warning: Do not point the valve towards you when releasing the nitrogen - it is under considerable pressure, and an oil mist will also be released.

Installation

10 Installation is the reverse of removal, noting the following.

a) Apply multi-purpose lithium grease to the pivot points.

b) Install the upper mounting bolt first, but do not tighten it until the lower mounting bolt is installed.

c) If the chain guard has been removed, make sure the chain guard bracket is correctly positioned (see illustration).

d) Tighten the lower mounting bolt (left-hand side) and nut (right-hand side) to the torque setting specified at the beginning of the Chapter.

e) Adjust the suspension as required (see Section 11).

f) Check the operation of the suspension before taking the machine on the road.

11 Rear shock absorbers - >

adjustment ||

Caution: Always ensure that both shock absorber settings are the same. Uneven settings will upset the handling of the machine and could cause it to become unstable.

Spring pre-load

1 Pre-load adjustment is made using a suitable slim bar (one of the Phillips screwdrivers provided in the toolkit will do) inserted into one of the holes in the pre-load adjuster ring on the bottom (550 models) or top (750 models) of the shock (see illustrations). There are five positions, each indicated by a step in the adjuster ring. Align the step required with the adjustment stopper.

2 On 550 models, to increase the pre-load, turn the spring seat anti-clockwise (towards the front of the bike). To decrease the preload, turn the spring seat clockwise. Position

2 is the standard setting for a rider of average build, riding solo.

3 On 750 models, to increase the pre-load, turn the spring seat clockwise (towards the front of the bike). To decrease the pre-load, turn the spring seat anti-clockwise. Position 2 is the standard setting for a rider of average build, riding solo.

11.4 Compression damping adjuster

11.6 Rebound damping adjuster

12.3 Remove the brake torque arm bolt 12.7a Remove the end cap ...

12 Swingarm -

removal and installation

12.3 Remove the brake torque arm bolt 12.7a Remove the end cap ...

Removal and lift the arm off

Note: Before removing the swingarm, it is advisable to perform the swingarm checks described in Chapter 1, Section 26.

1 On 550 models, remove the exhaust system, and on 750 models, remove the silencers (see Chapter 3).

2 Remove the rear wheel (see Chapter 6).

3 Remove the nut and the bolt securing the brake torque arm to the swingarm and lift the torque arm off the swingarm (see illustration). Support the brake caliper, caliper bracket and torque arm assembly so that it does not impede removal of the swingarm, making sure that no strain is placed on the hose.

11.4 Compression damping adjuster

11.6 Rebound damping adjuster

Compression damping

4 Compression damping adjustment is made by turning the adjuster on the top of the shock absorber (see illustration). There are four positions. Position 1 is the softest setting, position 4 the hardest.

5 Turn the adjuster until the number required aligns with the index mark on the shock. Do not set the adjuster in between any of the positions. Position 1 is the standard setting.

Rebound damping

6 Rebound damping adjustment is made by turning the adjuster on the bottom of the shock absorber (see illustration). There are four positions, denoted by Roman numerals. Position I is the softest setting, position llll the hardest.

7 Turn the adjuster until the number required is visible and clicks into position. Do not set the adjuster in between any of the positions. Position I is the standard setting.

4 Unhook the lower end of the brake light switch spring and position the spring out of the way.

5 Supporting the swingarm, remove the rear shock absorber lower mounting bolts (see Section 10). Also remove the chainguard if required (see Chapter 7).

6 Before removing the swingarm it is advisable to re-check for play in the bearings. Any problems which may have been overlooked with the checks made with the wheel and shock absorbers in place (see Chapter 1) are highlighted with these components removed.

7 Remove the swingarm end caps (see illustration). Unscrew the nut on the left-hand end of the swingarm pivot bolt, and on 750 models remove the washer (see illustration). With the aid of an assistant to support the swingarm if required, drift the pivot bolt out and withdraw it from the right-hand side of the frame (see illustration). Note the positions of any breather and drain pipes and move them aside if necessary, then manoeuvre the swingarm out of the back of the machine.

8 Check the condition of the chain slider on the front of the swingarm and replace it if it is worn or damaged (see illustration).

12.7b ... then unscrew the nut

12.7c ... and withdraw the pivot bolt

12.8 Replace the chain slider if worn or damaged

9 Inspect all components for wear or damage (see Section 13).

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