  |   
   
 |   |      
 |   Changing 
head bearings  Original article submitted by 
Macca 
  |  If you've got the wobbles in sweeping 
corners or knocking noises when braking, chances are your head bearings are at 
fault. The trickiest part is that during inspection or replacement the front end 
of the bike has to be off the ground. How you do it depends on you, who 
you know and what you've got. I am lucky because i use a sling over an iron girder 
and winch it up, but however you do it, bear in mind that you will be working 
in the headstock area A LOT, so it must be as stable as possible but allow full 
access to every component at wierd angles. It's better to suspend it with the 
weight bearing down WITH the support, rather than the weight bearing down ONTO 
the support. And remember the forks are coming off so it will need to be 
high enough off the ground to allow them to drop clear. You SO dont wanna be adjusting 
the support with the front end attached and flapping around. To do the job 
you will need a few vital bits: - New bearings (no shit, Sherlock!)
 - Quality 
clean grease
 - C-spanner
 - A drift (straight metal bar approx 12mm 
dia 12" long)
 
 First thing, take off the petrol tank and upper 
fairings. Loosen every bolt that attaches anything to anything from the handle 
bars forward ('cept brake unions!!!!) Install your method of raising the front 
and lift it up to approx 18". Give the bike a hard shake, it's better to 
find out if the system is good with the front wheel attached and the sidestand 
down.  |  
    
 Click 
the thumbnails to view full-size pictures  |  Next 
thing is to undo the two sunken allen bolts in the top yoke to release the clip-ons 
and then remove the top yoke itself. Now is also a good time to undo the brake 
calipers and loosen the pinch bolts on the bottom yoke all the way out. Release 
the pinch bolts on the clip ons and wiggle the forks down so the bars will be 
able to come off the top of the stanchions. Slide the fork assembly out from the 
bike and stand it up somewhere. |    
 Click 
the thumbnails to view full-size pictures  |  Now 
you need the C-spanner to slacken off the two locking washers on the steering 
stem, take them off and the top bearing will be loose on the stem, remove it and 
slide the bottom yoke and stem out. One bearing will be loose on the top 
of the headstock (nice bearing); one is pressed onto the bottom of the stem (bastard 
bearing). The races are the shiny inserts in the top and bottom of the headstock 
(when wiped clean of grease).  Old bearings on the... erm... right. New 
races on the... uummm... left.  |    
 Click 
the thumbnails to view full-size pictures  |  Next 
thing is to remove the old races from the headstock. Use the drift and tap the 
bottom one out from the top of the headstock and the top one out from underneath. 
Make sure you tap them quite gently and in circles, they will move slowly at first, 
just keep tapping around the edge and they will pop out. To remove the bottom 
bearing from the headstock is quite tricky. My only advice is don't be shy, the 
thing was pressed on at the factory and you aint gonna use it again. Just make 
sure you do not damage the yoke or stem in the process. Doing it by hand is preferable 
to using a power tool, you have more control and a better feel for when it goes. 
I use a cold chisel and tap round the base in the same way as the races, holding 
the yoke secure in a soft jawed vice. Once you have got this far, have a 
smoke and a cuppa, then clean EVERYTHING you have taken off, you prolly ain't 
going this far in for a long time and there will be no visible signs of all this 
hard work so while you're here... A big hint for installation is to use 
the old components as drifts to install the new ones. A bearing turned upside 
down is the same diameter as the new one going in and will absorb any impact damage. Also 
make sure that any washers under bearings are put on before the bearing is. Re-grease 
the headstock and slide the new bearing onto the stem as far as it will go. Slide 
the old bearing on upside down and tap the new one home until it is flush with 
the stem base.  |     
 Click 
the thumbnails to view full-size pictures  |  Grease 
the grooves the races sit in and tap home the new ones until they are flush all 
the way round the inner collar. Now give all the new components a good coating 
of grease and work it into the bearings. Reassemble the front end in reverse 
order that you dismantled it. Once everything is back together, tighten 
the fork clamp bolts all the way and the headstock locking nuts finger tight, 
then lower the bike to the floor. This will allow the bearings to sit properly 
in the races. Tighten everything to Mr Yamahamotosan's enlightened torque 
settings (ahem) and re-check everything is secure. You will notice some 
unusual handling charactaristics shortly after carrying out this procedure but 
they are temporary and you will become accustomed to them quickly. Symptoms include 
actually going where you are pointing mid-corner, holding the line and smooth 
steering. The sound of a whore's headboard banging during braking is also likely 
to disappear. Now you can go do stuff like this again.  
 Click 
the thumbnail to view full-size picture  Yay.
  |   
  |     |     | 
   
 www.exup1000.co.uk is owned and 
run by EXUP enthusiasts, for EXUP enthusiasts  Hosted by Digital Picsel 
 |