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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Mount the lower triple clamp, upper steering head bearing, protection ring,
O-ring, upper triple clamp and the blind screw.
Tighten the collar screw on the lower triple clamp to 60 Nm.
Mount the fork legs and tighten the clamp screws on the lower triple clamp
to 12 Nm in 3 stages.
Adjust the steering head bearing without clearance (see: Checking and adjust-
ing the steering head support) and tighten the clamp screws on the upper
triple clamp to 17 Nm in 3 stages.
Mount the front wheel fender and tighten the screws to 10 Nm.
Mount the hand brake cylinder and tighten the screws to 10 Nm.
Mount the staring number plate.
Mount the front wheel (see: Dismounting and mounting the front wheel).
Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put the motorcy-
cle on a stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. To adjust the 5 clamping screws [1] and [3], loosen
the upper triple clamp and turn the end screw [2] until no play is left. Don’t
tighten the steering stem bolt all the way, otherwise the bearings will be dam-
aged. With a plastic hammer, lightly tap on the triple clamp to release ten-
sion. Retighten the five pinch bolts to 15 Nm (SX) / 20 Nm (EXC, XC-W).
– IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY,
THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND
CAN GET OUT OF CONTROL.
– A PLASTIC INSERT IN THE THREAD OF THE CLAMPING SCREW [3] MAKES IT
SELF-LOCKING. THE CLAMPING SCREW MUST BE REPLACED IF IT CAN BE
TURNED IN BY HAND.
IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI-
ODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME
WILL BE DESTROYED.
The steering head bearings should be regreased at least once a year
(e.g. Motorex Long Term 2000).
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