ASSEMBLY
TOOL NAMEPART NUMBER
STEERING HEAD BEARING RACE
INSTALLER
HD-39302
SPECIAL PURPOSE GREASEHD-99857-97
1. Pack the new bearings with SPECIAL PURPOSE
GREASE (Part No. HD-99857-97).
NOTE
Press only on inner bearing race or damage to bearing will
occur.
2. See Figure 2-89. Install the lower dust shield (11) and new
bearing (10) on the fork stem (12).
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)
3. Lubricate the races with engine oil. Install the new races
using STEERING HEAD BEARING RACE
INSTALLER (Part No. HD-39302).
INSTALLATION
Properly adjust fork stem bearings. Improper adjustments
affect stability and handling, which could result in death
or serious injury. (00301a)
1. See Figure 2-89. Insert the stem and bracket assembly
into the frame steering head and install the upper bearing
(7) and dust shield (6). Secure with the adjusting nut (5).
Tighten the adjusting nut until there is no noticeable shake
or freeplay between bearings and races. Fork stem must
turn freely from side to side.
NOTE
The washer under the fork stem nut is a special hardened
material. Never replace this washer with a common flat washer.
Doing so may allow the fork stem nut torque to loosen resulting
in loss of steering control.
2. Install upper bracket (4), hardened flat washer (2).
NOTE
• Original equipment fork stem nut has a blue coating. If a
new nut is being installed, the replacement nut will not
have a coating.
• Whenever the stem nut is loosened or removed, the
threads must be lubricated with anti-seize lubricant prior
to assembly and tightening.
3. Lubricate threads of fork stem nut (3) with a light coating
of anti-seize lubricant. Install stem nut and tighten securely.
4. Install the headlamp assembly. See 8.9 HEADLAMP.
5. Install fork sides. See 2.17 FRONT FORK.
6. Adjust steering head bearings. See 1.20 STEERING HEAD
BEARINGS.
7. Tighten fork stem nut to 70-80 ft-lbs (94.9-108.4 Nm).
8. Install the fork stem cap.
9. Align headlamp. See 1.23 HEADLAMP ALIGNMENT.
2-60 2008 Dyna Service: Chassis
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