Fork Stem And Bracket Assembly - Buell 2002 P3 Service Manual

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FORK STEM AND BRACKET ASSEMBLY

REMOVAL/DISASSEMBLY
1. Remove seat. See 2.28 SEAT.
2. Disconnect battery.
11 1
WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
3. Remove dash. See 2.27 INSTRUMENT PANEL.
4. Remove handlebars. See
5. Remove fork assembly. See
6. Remove ignition switch assembly. See
HEADLAMP KEY SWITCH.
7. See Figure 2-90. Remove screw (9) and capnut (4).
8. Support lower triple clamp (6) and remove upper triple
clamp (5).
9. Remove upper dust shield (3) and upper bearing (1).
10. Lower triple clamp can be removed.
11. Remove lower bearing (1) and lower dust shield (3) from
lower triple clamp.
CLEANING AND INSPECTION
1. See Figure 2-90. Clean the dust shields (3), bearing
cups (2), fork stem and lower triple clamp (6) and frame
with solvent.
2. Carefully inspect bearing races and assemblies for pit-
ting, scoring, wear and other damage. Replace damaged
bearings (1) as a set (1, 2 and 3).
3. Check the fork stem and lower triple clamp (6) for dam-
age. Replace if necessary.
ASSEMBLY/INSTALLATION
1. If removed, install new bearing cups into frame steering
head using STEERING
INSTALLER (Part No. HD-39302).
2. Liberally coat the bearing cones (1) with grease using
WHEEL BEARING PACKER TOOL (Part No. HD-33067).
Work the grease into the rollers.
3. Install lower bearing.
a. Place lower bearing dust shield (3) over fork stem.
b. Find a section of pipe having an inside diameter
slightly larger than the outside diameter of the fork
stem.
c. Press bearing (1) with small end up onto fork stem
and lower triple clamp (6). Use the pipe as a press-
on tool.
4. Insert lower triple clamp (6) through the steering head.
Install the upper bearing (1) with small end down and
dust shield (3) onto fork stem.
2-50 2002 Buell P3: Chassis
WARNING
2.30 HANDLEBARS.
2.17 FRONT FORK.
7.6 IGNITION/
HEAD BEARING RACE
a0137x2x
9
7-10 ft-lbs
(10-14 Nm)
8
13-16 ft-lbs
(18-22 Nm)
1
2
3
1. Bearing
2. Bearing Cup
3. Dust Shield
4. Cap Nut
5. Upper Triple Clamp
Figure 2-90. Fork Stem and Bracket Assembly
5. Apply LOCTITE THREADLOCKER 243 (Blue) to fork
stem. Loosely install upper triple clamp (5) using cap nut
(4).
6. Install fork assemblies. See
7. Tighten cap nut (4) until the bearings have no free play.
Make sure the fork stem turns freely, then tighten the fork
stem clamp screw (9).
8. Check steering head bearing adjustment.
9. Install handlebars. See
10. Install dash. See 2.27 INSTRUMENT PANEL.
11. Connect battery negative cable.
12. Install seat. See 2.28 SEAT.
2.18
To Adjust:
4
48-52 ft-lbs
(65-71 Nm) then
loosen and re-tighten
to: 28-32 ft-lbs
(38-43 Nm)
Blue Loctite
5
3
2
1
22-29 ft-lbs
7
(30-39 Nm)
6
6. Lower Triple Clamp
7. Pinch Screws (2)
8. Pinch Screws (2)
9. Center Cap Pinch
Screw
2.17 FRONT FORK.
2.30 HANDLEBARS.