10. Steering head bearings: refitting

  1. To refit the bearing outer races assemble a drawbolt consisting of a pair of thick steel washers which are large enough to fit over the end of the steering head lug, a bolt long enough to pass through the head lug, both washers and one outer race, and a large nut.
  2. Ensuring that it is square to its housing in the steering head lug draw the bottom bearing outer race into the head lug until it seats fully. Do not forget to fit the Fluidbloc (where fitted) before repeating the procedure to refit the top bearing outer race.
  3. Both inner races must be heated to 80°C (176°F) to refit them. To fit the lower bearing inner race a tubular drift must be found that will fit over the steering stern and yet bear only against the bearing inner race itself, not touching the rollers or cages. Refit the dust seal (where fitted) heat the bearing and drop it over the steering stern (ensuring that it is the correct way up) then tap it firmly down on to the bottom yoke; there must be no clearance between the bearing and the yoke.
  4. The top bearing is fitted in a similar manner to the adjuster nut; again there must be no clearance between the bearing and the nut top cover.
  5. Thoroughly grease all bearings after they have cooled, but be careful to keep grease away from the 'Fluidbloc' (where fitted). Where a Fluidbloc has been fitted to an early K75C model, wrap a thin layer of tape around its threads before refitting the steering stern.
  6. On early 75 models and all 100 models check that the bottom bearing is greased and refit the bottom yoke to the steering head. Remove the tape (if applicable). Heat the top bearing to 80°C (176°F) and drop it over the stern upper end. Tap it into place and refit the circular adjuster nut. Allow the bearing to cool, pack it with grease, if necessary, and tighten the nut hard to preload the bearings then slacken it fully and re-tighten it until all free play is just eliminated.
  7. On early 75 models and all 100 models check that the bottom bearing is greased and refit the bottom yoke to the steering head. Remove the tape (if applicable). Heat the top bearing to 80°C (176°F) and drop it over the stern upper end. Tap it into place and refit the circular adjuster nut. Allow the bearing to cool, pack it with grease, if necessary, and tighten the nut hard to preload the bearings then slacken it fully and re-tighten it until all free play is just eliminated.
  8. On later 75 models check that the bearings are greased and carefully refit the bottom yoke to the steering head. Refit the circular adjuster nut with the top bearing and locking sleeve. Again tighten the adjuster nut hard to preload the bearings, then slacken it fully and retighten it until all free play is just eliminated.
  9. On all models refit the top yoke, followed by the top bolt (early 75 models and all 100 models) or locknut (late 75 models); do not tighten them until adjustment is complete.
  10. Refit the handlebars, ensuring that the punch mark is aligned on the inside of the left-hand clamp, between the joint faces of the two clamps.
  11. Refit the brake pipe to the steering head, fasten the plastic nut or retainer to secure it and connect the master cylinder brake hose again, using new sealing washers. Refill the brake system with fresh fluid, check that the spacers are in place between the brake pads, and bleed the brake system until. normal lever pressure is restored. If the handlebars are kept on full left lock, the master cylinder will be the highest point in the system which will aid this procedure. Be very careful to check that the brakes are working correctly before taking the machine out on the road.
  12. Refit the front forks, mudguard and fork brace. See Section 6 - Front forks: refitting and Section 7 - Front forks: aligning the damping components of this Chapter. Refit the front wheel as described in Chapter 9 - Wheels & Brakes - 2--Front wheel: removal and refitting.
  13. Adjust the steering head bearings as described in Maintenance - Major Service - 16---Check the steering head bearings, then refit all disturbed fairing or headlamp housing components, the handlebar panel and ignition switch and the fuel tank.
  14. Check that the front brakes, the suspension, the steering and all controls work properly and are adjusted correctly before taking the machine out on the road. All fasteners should be securely tightened to their respective torque wrench settings, if available.




Different types of grease suitable for steering head bearings