Tool

Use a ratchet-type tool when installing the fork top bolt. This makes it unnecessary to remove the tool from the bolt whilst threading it in, thus making it easier to maintain a downward pressure on the spring.

8.7 Unscrew the steering stem bolt and remove the washer

8.2 The brake hose union is secured by two bolts

8.7 Unscrew the steering stem bolt and remove the washer

8.2 The brake hose union is secured by two bolts

8.8a Remove the locknut (A), adjuster ring (B) and the bearing cover (C)

8.8b Displace the O-ring and discard it

8.10 Remove the upper bearing

8.8a Remove the locknut (A), adjuster ring (B) and the bearing cover (C)

8.8b Displace the O-ring and discard it

8.10 Remove the upper bearing

8.12a Lift the steering stem up into the head

8.12b Fit the bearing cover ...

8.11 Apply grease liberally to the bearings

8.12a Lift the steering stem up into the head

8.12b Fit the bearing cover ...

8.11 Apply grease liberally to the bearings

8.13 Fit the top yoke onto the steering stem

8.14 Tighten the steering stem bolt to the specified torque setting

9.4 Drive the bearing races out with a brass drift as shown

9 Steering head bearings -

inspection and replacement ^

8.13 Fit the top yoke onto the steering stem

Installation

11 Smear a liberal quantity of grease on the bearing races in the frame. Work grease well Into both the upper and lower bearings (see illustration).

12 Carefully lift the steering stem/bottom yoke up through the frame (see illustration). Install the upper bearing in the top of the steering head, then fit the new O-ring (see illustration 8.8b). Install the bearing cover and thread the adjuster ring, with its stepped side facing down, and locknut on the steering stem (see illustrations). Tighten the adjuster ring as required until all freeplay in the forks is removed, yet the steering is able to move freely from side to side. The object is to set the adjuster ring so that the bearings are under a very light loading, just enough to remove any freeplay. Tighten the locknut against the adjuster ring finger-tight only. Turn the steering stem through its full lock five or six times, then recheck for freeplay. Check

Inspection

1 Remove the steering stem (see Section 8).

2 Remove all traces of old grease from the bearings and races and check them for wear or damage.

3 The races should be polished and free from indentations. Inspect the bearing rollers for signs of wear, damage or discoloration, and examine the bearing roller retainer cage for signs of cracks or splits. Spin the bearings by hand. They should spin freely and smoothly. If there are any signs of wear on any of the above components both upper and lower bearing assemblies must be replaced as a set. Only remove the races if they need to be replaced - do not re-use them once they have been removed.

Replacement

4 The races are an interference fit in the steering head and can be tapped from position with a suitable drift (see illustration). Tap firmly and evenly around each race to ensure that it is driven out squarely. It may prove advantageous to curve the end of the drift slightly to improve access.

5 Alternatively, remove the races using a slide-hammer type bearing extractor; these can often be hired from tool shops.

9.4 Drive the bearing races out with a brass drift as shown

8.14 Tighten the steering stem bolt to the specified torque setting and adjust the bearings as described in Chapter 1 after installation is complete. Caution: Take great care not to apply excessive pressure because this will cause premature failure of the bearings.

13 Install the top yoke onto the steering stem (see illustration). Install the steering stem bolt and its washer and tighten it finger-tight only at this stage (see illustration 8.7). Temporarily install one of the forks to align the top and bottom yokes, and secure it by tightening the bottom yoke clamp bolts only.

14 Tighten the steering stem bolt to the specified torque setting (see illustration).

15 Install the front forks (see Section 6).

16 Install the remaining components and assemblies in a reverse of the removal procedure, referring to the relevant Sections and Chapters.

17 Carry out a check of the steering head bearing freeplay as described in Chapter 1, and if necessary re-adjust.

10.4b ... and remove the shock absorber

10.4a Unscrew the upper mounting bolt...

9.7b ... or remove it using a bearing puller

9.7a Remove the lower bearing as shown ...

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

Get My Free Ebook


Post a comment