8. Steering head bearings: removal

  1. Owners of machines with fairings are strongly advised to remove the fairing components to prevent any risk of damage.
  2. Remove the fuel tank. See Manual - Chapter 5 - Fuel tank: removal and refitting.
  3. Remove the front fork legs. See Section 2 - Front forks: removal of this Chapter.
  4. Carefully prise out the ignition switch surround and disengage the switch from the handlebar panel with a small screwdriver, then remove the panel mounting screws and withdraw the panel.
  5. On K75, K75C, K75T and K100 models remove the headlamp surround/handlebar fairing, then remove its two fixing bolts and withdraw the headlamp unit. disconnecting the electrical leads to release it. Disconnect the horn wires, slacken the horn mounting bolts and remove the single screw securing the connector plug cover to the underside of the instrument panel. Withdraw the cover and unplug the connectors, then unscrew four Allen screws or hexagon-headed bolts securing the housing rear cover to the fork yokes. Withdraw the rear cover complete with the instrument panel, manoeuvring the panel clear of the bottom mounting bracket.
  6. Disconnect the brake hose at the unions on the steering stem upper end and either plug the hose or wrap it tightly in a plastic bag or similar so that brake fluid cannot leak out. Unscrew the plastic nut (early 75 models and all 100 models) or release the retainer (later 75 models) at the top of the steering stem and pull the brake pipe down through the steering head, taking care not to splash brake fluid.
  7. Remove the handlebar clamp bolts and bring the handlebars to the rear, clear of the steering head area, ensuring that all cables and wiring are out of the way. The fork yokes should now be completely clear and ready for removal.
  8. On all 100 models and early 75 models unscrew the steering stem top bolt, tap the top yoke upwards off the steering stem using only a soft-faced mallet, unscrew the circular adjusting nut and pull the bottom yoke downwards out of the steering head; it may be necessary to use a soft-faced mallet to tap the steering stem down through the bearings. Withdraw the top bearing.
  9. If working on an early K75C model that has been subsequently fitted with a 'Fluidbloc' damper (identified by the two bolt heads protruding from the steering head lug) wipe all traces of grease away trom the steering stem and wrap a thin layer of insulating tape around the threads to prevent them damaging the damper rubber as they pass through it.
  10. On later 75 models unscrew the locking sleeve locknut and tap the fork top yoke upwards off the steering stem, then slacken the locking sleeve and unscrew the bearing adjuster nut while pulling the bottom yoke downwards out of the steering stem. The top bearing must be driven off the adjuster nut using a hammer and a pin punch passed through the holes in the nut top cover
  11. The bearing outer races can only be extracted using a slide-hammer or similar puller which has an internally-expanding adaptor of the necessary size.
  12. To remove the bottom bearing thoroughly clean the whole steering stem and mark its installed position in the bottom yoke next to the slot for the steering lock. Heat the assembly to 120 - 130'C (248 - 266'F) and drive or press the steering stem downwards through the bottom yoke until the bearing is released.
  13. Before the yoke cools down, use a 30 mm (1.2 in) drift to tap the stem back into its previously marked position; the circlip should locate against the yoke underside.

8.4a Prise off switch surround to release ignition switch from handlebar cover ...

8.4b ... then remove panel mounting screws and withdraw panel

8.6 Brake hose must be disconnected before fork top yoke can be removed.