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Repacking your headrace bearingsNo
need to book your bike into a garage, this can be done quite easily
in your own garage The following information is to repack the headrace bearings on a 1999 Yamaha R1 fitted with an Ohlins steering damper and a Harris fitting kit You should get a small tub or similar to put all the bolts in, or you could line them up on a bench (if you have one) Firstly get an old towel or a rag and place it over the tank, as you don't want this scratched Undo the 5mm allen bolt connecting the Steering Damper to the Harris bracket Undo the two 5mm allen bolts connecting the Upper Plate to the top of the forks Undo the 36mm Steering stem nut Undo the 6mm Upper Plate pinch bolts, one on each side,see illustration Undo the 5mm allen bolt which attaches the Brake Fluid Reservoir to the Upper plate, see illustration Lift off the Harris Cover plate and Steering Damper and place to one side The Upper plate can then be gently lifted off and moved forward out of the way, see illustrations You can (if you haven't got a bike lift) place a trolley jack under the exhaust(putting a small piece of wood between the jack and the exhaust to protect it, see illustration) and raise the machine just enough so that the front wheel is just touching the ground Make sure you have a helper with you to hold the bike just in case it falls Take off the Lock washer Undo the Upper Ring Nut with either a C Spanner or a Ring Nut Wrench, see illustration Take off Rubber washer Undo the Lower Ring Nut gently, as you do this the Steering Stem will move slightly in the Steering Head Take off the Lower Ring Nut and the Bearing Cover, see illustration Lift out the Bearing Inner race The Upper bearings can now be removed, see illustration
Check the bearing for wear and pitting, if the bearings are blue or black then they need to be replaced If the Upper bearings look ok then the lower bearings should also be ok, as these should be replaced in pairs Now jack up the bike enough so that you can get to the Lower bearings You should use a Lithium Based Grease for the Repacking Now gently pack new grease into each and every bearing, spinning each bearing in turn and the whole bearing itself Grease the bearing races as well Get the Upper bearing and slowly pack new grease into each and every bearing, and the bearing races as well, see illustration Gently let the jack down so that the front wheel is just touching the floor Insert the Upper Bearings and the Inner Race onto the Steering Stem, see illustration You may have to gently roll the front wheel back and forward in order to seat the Bearings correctly Once these are in place you can install the Lower Ring Nut Do this up hand tight then let the jack down and move it out of the way Move the handle bars from lock to lock to make sure that nothing is trapped If all is well then you can tighten the Lower Ring Nut up to Specification(Ring Nut Wrench and Torque Wrench) Make sure you have the Torque Wrench set at a right angle to the Ring Nut Wrench Loosen the Lower Ring Nut completely and then retighten it to the next Specification Install the Rubber Washer and the Upper Ring Nut The Upper Ring Nut has to be done finger tight and just enough to squeeze the Rubber Washer, making sure the flats on the Ring Nuts are aligned Install the Lock Washer Again move the hadle bars from lock to lock to make sure that nothing is trapped and the handle bars move smoothly If all is well then continue , if not go back and find out what is wrong Reinstall the Upper Plate, you may have to gently tap this back on with your hand or a rubber mallet until it is seated properly Now Install the 36mm Steering Stem Nut to Specification Do up the two 6mm Upper PLate pinch bolts to Specification Reinstall the 5mm allen bolts which holds the Brake Fluid Reservoir Reinstall the Harris cover plate and the two 5mm allen bolts Reinstall the 5mm Steering Damper allen bolt Recheck the movement of the handle bars and if that is ok then you are done Remove rag or towel from tank and dust off your bike Go and get cleaned up and you are ready to go back on the road Safe riding !
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