Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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14-8 STEERING
Steering Stem
• Apply grease the lower ball bearing [A] and install it onto
the stem.
• Apply grease to the upper ball bearing [B] and inner race
[C].
• Install the stem [A] through the head pipe and install the
ball bearing [B] and inner race [C] on it.
• Install the stem cap [D] and steering stem nut [E].
• Settle the inner races in place as follows:
○Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a stem nut wrench [A] in the direction shown.
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001–1100
Torque - Steering Stem Nut: 27 N·m (2.75 kgf·m, 20 ft·lb)
• Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
• Hand tighten the stem locknut until it touches the claw
washer.
• Tighten the stem locknut clockwise until the claws are
aligned with the grooves (ranging from 2nd to 4th) of stem
nut [D], and bend the 2 claws downward [E].
Install the stem head.
• Install the washer, and tighten the stem head bolt with
specified torque.
Install the steering stem head bolt plug.
• Install the front fork (see Suspension chapter).