Warning - General - Stabilise Motorcycle - including DO NOT support on non integral parts

1. Raise and support the front of the motorcycle.
2. Remove the fixings that attach the handlebar clamp to the upper yoke. Detach the clamp and release the handlebar.
3. As an assembly, raise the handle bars until clear of the upper yoke. Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
4. Loosen the upper yoke pinch bolts.
warning
Do not loosen the lower yoke fixings because the forks will no longer support the weight of the motorcycle.If this happens, the motorcycle could fall over and causing damage or personal injury.
notice
Take care when you remove the upper yoke centre nut, to make sure that the centre nut and upper yoke do not become scratched.Protect the surfaces with a suitable cloth or tape to prevent scratching.
5. Remove the upper yoke centre nut from the steering stem.



Upper yoke centre nut

6. Ease the upper yoke and instrument assembly from the forks and support them while detached.
notice
When you adjust the bearing free play, make sure that the threaded part of the stem is free from grease.
notice
Keep the torque wrench at 90 degrees to the centre line of service tool T3880750 when you tighten the adjustment nut in the stage that follows. This will apply the correct torque to the adjustment nut.
7. Adjust the bearing free play as follows, using service tool T3880023 and service tool T3880750:
* Remove the lock nut using service tool T3880023.
* Remove and discard the washer.



Adjuster nut Lock nut T3880023 - 50 mm Socket

* Thoroughly clean the threads on the steering stem.
* Loosen the adjuster nut using service tool T3880750, then tighten to 40 Nm. Keep the torque wrench at 90 degrees to the centre line of the tool.
* Loosen the adjuster nut using service tool T3880750, then tighten to 10 Nm. Keep the torque wrench at 90 degrees to the centre line of the tool.



T3880750 - Headstock Service Tool Torque wrench

* Fit a new tab washer and the lock nut.
warning
It is essential that the adjuster nut is not over-tightened.If the adjuster nut is over-tightened it will cause a pre-load on the headstock bearings.This will cause tight steering, which may lead to loss of motorcycle control, which could result in serious injury or death.
* Position service tool T3880023 to the lock nut and tighten to 10 Nm.



Adjuster nut Lock nut T3880023 - 50 mm Socket

* Add an alignment mark between the adjuster nut and the lock nut.
* Position service tool T3880750 to the adjuster nut.
* Whilst restraining the lock nut with service tool T3880023, turn the adjuster nut with service tool T3880750 and proprietary wrench counter-clockwise by 45 degrees.
* Whilst restraining the lock nut with service tool T3880023, turn the adjuster nut with service tool T3880750 and torque wrench counter-clockwise and tighten to 45 Nm. Keep the torque wrench at 90 degrees to the centre line of the tool.



Adjuster nut Lock nut T3880023 - 50 mm Socket T3880750 - Headstock Service Tool

* Make sure that the alignment mark between the adjuster nut and lock nut is no longer aligned.
8. Refit the upper yoke and instrument assembly to the forks.
9. Fit the upper yoke centre nut and tighten to 90 Nm.
10. Tighten the upper yoke pinch bolts to 26 Nm.
11. Locate the handlebar assembly in the lower halves of the clamps. Fit the upper clamps and bolts.
12. Rotate the handlebars so that the alignment mark on the handlebar aligns with the split line.
13. Tighten the front clamp bolts to 26 Nm, then the rears.



Alignment mark Split line

14. Recheck the bearing adjustment (see Steering Head Bearing - Check).