HOME ASSEMBLY sm03178 TOOL NAME PART NUMBER STEERING HEAD BEARING RACE INSTALLER HD-39302 1. Lubricate outside of new steering head bearing races with lubricant provided or engine oil. 2. See Figure 2-146 . Assemble STEERING HEAD BEARING RACE INSTALLER (Part No. HD-39302) and bearing races on tool's draw down bolt through steering head. Orient races so lettered edges are at bottom of steering head bore in steering head. Figure 2-146. Steering Head Bearing Race Installer (HD-39302) 3. Continue to thread nut on draw down bolt until races fit, and are parallel to steering head bore. 4. Slowly tighten nut while stopping periodically to check for bearing race to steering head parallelism.
INSTALLATION 1. See Figure 2-106 . Insert fork stem (10) and lower triple clamp (14) assembly into frame steering head and install a new upper bearing (8) and new seal (7). Secure with adjusting nut (6).Tighten adjusting nut until bearings have no noticeable shake. Fork stem must turn freely from side to side. Properly seat bearing cups in steering head bore. Improper seating can loosen fork stem bearings adversely affecting stability and handling, which could result in death or ser- ious injury. (00302a) 2. Install upper triple clamp (4), and washer (3). 5.
When bearing races are fully seated in bore of steering head, pack new bearings with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (HD-99857-97). Properly adjust fork stem bearings. Improper adjustments affect stability and handling, which could result in death or serious injury. (00301a) NOTE Do not use a sleeve that is larger than the inner race of the bearing or bearing cage may be damaged. A damaged bearing cage will require replacement of both the cage and the bearing. 3. Thread on and finger tighten fork stem nut (2). 6. Install a new lower seal on fork stem. 4. Fasten brake hose bracket to lower triple clamp (14). Tighten bolt to 53-89 in-lbs (6-10 Nm). 7.
Use sleeve or drift that will contact only inner race of bearing and press lower bearing into place on fork stem. 5. Install fork tube assemblies into bottom and top triple clamps (4, 14). NOTE A sleeve (drift) to press on the lower fork stem bearing can be constructed out of thick walled pipe, 22.86 cm (9.0 in.) long with an inside diameter of 25.65 mm (1.010 in.) and an outside diameter of 31.75 mm (1.250 in.). 6. See Figure 2-106 . Fork tube protrusion should project 6.4- 9.7 mm (0.25-0.38 in) for all except VRSCF and 2.0 mm (0.78 in) from the flat spoin on the upper triple clamp for VRSCF models. Tighten pinch bolts to per appropriate fork rebuild procedure. 7.
Install handlebar brackets, handlebars, clutch and brake lever assemblies. 8. Install front fender and bracket. See 2.31 FRONT FENDER . 9. Install front wheel assembly. See 2.23 FRONT WHEEL . 10. Install right and left front brake calipers. See 2.16 FRONT BRAKE CALIPER . 11. See Figure 2-106 . Adjust steering head bearing fall away. Tighten or loosen until the fall away measurement is within . 51-102 mm (2-4 in.) and tight to 44 Nm (32.5 ft-lbs) . See 2. 2009 VRS en steering stem pinc 34 STEERING HEAD C Service: Chassis