Fork Stem And Bracket Assembly - Buell 2002 S3T Service Manual

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FORK STEM AND BRACKET ASSEMBLY

REMOVAL/DISASSEMBLY
1. Remove fork assemblies. See
2. Remove handlebar clamp. See
3. See Figure 2-56.
(7, 11), fork stem bolt (1) and upper triple clamp (2).
4. Remove upper dust shield (3) and roller bearing (4).
5. Remove lower roller bearing.
a. Remove two lower triple clamp screws (7). Pull the
lower triple clamp (6) downward.
b. The lower bearing cone is a press fit on fork stem.
Chisel through outer bearing cage to allow rollers to
fall free.
c. Apply heat to remove the remaining portion of bear-
ing cone. Continuously move flame around its entire
circumference until bearing falls free.
d. Remove lower dust shield (3).
6. If replacement of bearing cups (5) is necessary, drive
cups from steering head using STEERING HEAD BEAR-
ING RACE REMOVER (Part No. HD-39301A) and UNI-
VERSAL DRIVER HANDLE (Part No HD-33416).
CLEANING AND INSPECTION
See 1.15 FRONT FORK
1. See Figure 2-56.
cups (5), 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 (4) as a set (3, 4 and 5).
3. Check the fork stem and lower triple clamp (6) for dam-
age. Replace if necessary.
ASSEMBLY/INSTALLATION
1. See Figure 2-56.
into frame steering head using STEERING HEAD
BEARING RACE INSTALLER (Part No. HD-39302).
2. Liberally coat the bearing cones (4) 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 (4) 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 (4) with small end down and
dust shield (3) onto fork stem.
5. Apply LOCTITE ANTI-SEIZE to fork stem bolt (1).
Loosely install upper triple clamp (2) using fork stem bolt.
2.16 FRONT FORK.
2.26 HANDLEBARS.
Remove all upper triple clamp screws
for adjustment procedures.
Clean the dust shields (3), bearing
If removed, install new bearing cups (5)
b0373x2x
1
11
4
5
3
10
8
9
1. Fork Stem Bolt
2. Upper Triple Clamp
3. Dust Shield (2)
4. Roller Bearing (2)
5. Bearing Cup (2)
6. Lower Triple Clamp
7. Lower Clamp Pinch Screws (2)
8. Steering Head Lock
9. Steering Lock Key
10. Set Screw
11. Small Pinch Screw
12. Upper Clamp Pinch Screws (2)
Figure 2-56. Fork Stem
6. Install fork assemblies. See
7. Check adjustment.
a. Install fork stem bolt (1).
b. Check bearing adjustment to tighten fork stem bolt
to proper tension. See
BEARINGS.
c. Make sure the fork stem turns freely, then tighten
the fork stem clamp screw (11).
8. Install and adjust handlebars. See
2002 Buell S3T: Chassis
2.17
2
3
12
5
4
6
7
2.16 FRONT FORK.
1.16 STEERING HEAD
2.26 HANDLEBARS.
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