Kawasaki Z1000SX - Service manual > Steering Stem

Stem, Stem Bearing Removal

• Remove:
  Upper Fairing (see Upper Fairing Removal in the Frame chapter)
  Upper Fairing Bracket (see Upper Fairing Bracket Removal in the Frame chapter)
  Meter Unit (seeMeter Unit Removal in the Electrical System chapter)
  Handlebar (see Handlebar Removal)
  Steering Stem Head Bolt Plug [A]
  Steering Stem Head Bolt [B] and Washer

• Remove:
  Front Forks (see Handlebar Removal in the Suspension chapter)
  Steering Stem Head
  Brake Hose Fitting Bolt [A]

• Bend the claws [A] of claw washer back.
• Remove the steering stem locknut [B].

  Special Tool - Steering Stem Nut Wrench: 57001-1100

• Remove the claw washer.

• Pushing up the stem base, and remove the steering stem nut [A] with stem cap [B].

  Special Tool - Steering Stem Nut Wrench [C]: 57001-1100

• Remove:
  Steering Stem [D]
  Upper Ball Bearing Inner Race and Ball Bearing

• To remove the ball bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head pipe, and applying it to both recess alternately hammer it to drive the race out.

NOTE

• If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.

• Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B].

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, 54.5 [B]: 57001-1077
   Head Pipe Outer Race Driver, 55: 57001 -1446

• 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

• Install the lower ball bearing [A] onto the stem.
• Grease the following.

  Inner and Outer Races
  Lower and Upper Ball Bearings

  • The lower and upper ball bearings are identical.

• Install the stem [A] through the head pipe and install the ball 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].

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 25 N*m (2.5 kgf*m, 18 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 the claw washer touches the steering stem nut.
• 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 steering stem head bolt.
• Install the front forks (see Front Fork Installation in the Suspension chapter).

NOTE

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

Torque -
 Upper Front Fork Clamp Bolts: 25 N*m (2.5 kgf*m, 18 ft*lb)
 Steering Stem Head Bolt: 108 N*m (11.0 kgf*m, 79.7 ft*lb)
 Lower Front Fork Clamp Bolts: 20 N*m (2.0 kgf*m, 15 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.

Steering Stem Warp

• 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 steering stem.

Stem Cap Deterioration, Damage

Replace the stem cap if its oil seal [A] shows damage.

See also: