Installation
1. Liberally apply lithium soap grease to the bear-
ings and races.
2. Install a new dust seal and the lower bearing
onto the steering stem.
3. Carefully slide the steering stem up through the
frame steering head (
Figure 52
).
4. Install the upper bearing (B,
Figure 51
) and the
bearing inner race (A).
5. Install the bearing cap (B,
Figure 50
) adjuster
ring nut (A).
6. Adjust the steering head bearings as follows:
a. Set a torque wrench at a right angle to the ring
nut wrench (
Figure 53
).
b. Seat the bearings within the steering head and
tighten the adjuster ring nut to 52 N•m (38
ft.-lb.).
c. Loosen the adjuster ring nut one turn.
d. Tighten the adjuster ring nut to 18 N•m (13
ft.-lb.).
7. Inspect the steering head as described in Chapter
Three. If there is any binding or looseness, disas-
semble and inspect the steering head as described in
this chapter.
8. Install the rubber washer (
Figure 49
) and the
locking ring nut (B,
Figure 48
). Tighten the locking
ring nut finger-tight. Check the slots on the locking
ring. They should align with those on the adjusting
ring nut. If they do not, tighten the locking ring nut
until alignment is achieved. If necessary, hold the
adjusting ring nut so it does not move when the slots
are aligned.
9. Install the lockwasher (A,
Figure 48
) so its fin-
gers are seated in the ring nut slots.
10. Install the upper fork bridge onto the steering
stem shaft. Loosely install the washer and the steer-
ing head nut (C,
Figure 41
).
11. Temporarily insert both fork tubes through the
lower and upper fork bridges.
NOTE
On XVS1100 models, a single pinch
bolt is used on each side of the lower
fork bridge.
12. Tighten the lower bridge pinch bolts (
Figure 54
) to
hold the fork tubes in position. Then tighten the steering
head nut (C,
Figure 41
) to 110 N•m (81 ft.-lb.).
13. Turn the steering stem by hand to make sure it
turns freely and does not bind. If the steering stem is
too tight, the bearings can be damaged; if the
steering stem is too loose, the steering will become
unstable. Readjust if necessary.
14. Remove the fork tubes and install them as de-
scribed in this chapter.
15. Install the front wheel (Chapter Ten) and fender
(Chapter Fourteen).
16. If removed, install the headlight bracket and the
brake hose union onto the lower fork bridge. Torque
the headlight bracket nuts to 7 N•m (62 in.-lb.) and
the brake hose union bolts to 7 N•m (62 in.-lb.).
17. On XVZ1100 models, install the front turn sig-
nal flasher assemblies onto the lower fork bridge (if
removed). Torque the front turn signal mounting
nut to 7 N•m (62 in.-lb.).
18. On XVZ1100A models, install the front turn sig-
nal bracket and cover (A,
Figure 46
). Feed the
flasher wires through the headlight housing as noted
during removal and torque the front turn signal
bracket bolts (B,
Figure 46
) to 7 N•m (62 in.-lb.).
326
CHAPTER ELEVEN
53
54
Torque wrench
Ring nut wrench
