Fork Stem And Bracket Assembly - Buell 2002 X1 Handbook

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FORK STEM AND BRACKET ASSEMBLY

REMOVAL/DISASSEMBLY
1. Remove steering head lock. See
LOCK.
2. Remove fork assemblies. See
3. Detach instrument support and handlebars. See
INSTRUMENT SUPPORT.
4. See Figure 2-66. Remove all upper triple clamp screws
(7, 11), fork stem bolt (1) and upper triple clamp (2).
5. Remove upper dust shield (3) and roller bearing (4).
6. 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).
7. 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 SUSPENSION DAMPING ADJUSTMENTS
adjustment procedures.
1. See Figure 2-66. Clean the dust shields (3), bearing
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.
2-42
2.18 STEERING HEAD
2.16 FRONT FORK.
2.26
for
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. Screw (4)
8. Steering Head Lock
9. Steering Lock Key
10. Set Screw
11. Screw
Figure 2-66. Fork Stem
2.17
2
3
7
5
4
6
2002 Buell X1: Chassis