Steering Head Bearings - Kawasaki KLR 650 Forum
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post #1 of 7 Old 08-20-2013, 10:50 AM Thread Starter
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Steering Head Bearings

Hey all
I'm replacing my friends Steering head bearings on her 2008 Gen 2. Everything has gone smoothly until I got to the races in the frame. How the hell do you get them out? There is no protruding lip to get a chisel on. Suggestions and experiences please.
Also doing her fork oil seals while I'm there. What's the best tool for hooking out the old oil seals? And what's the best weight oil to use on a standard set up? I was thinking of going a bit thicker with 15w. What would be the air gap measurement for that? I think that's enough questions for now.
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post #2 of 7 Old 08-20-2013, 11:10 AM
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Seems to me I've used a long drift or a long socket extension to drive them out from the back side. A little heat on the steering head might help too.
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post #3 of 7 Old 08-20-2013, 11:34 AM
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if you have access to a welder, you can put a few tacks right on the race, then use a drift from the other side. make sure not to weld the race to the frame though

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post #4 of 7 Old 08-20-2013, 11:53 AM
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Kawasaki makes a tool that is pretty expensive, but the Park race tool does a pretty good job without screwing things up.

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post #5 of 7 Old 08-20-2013, 02:26 PM
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Quote:
Originally Posted by UKbri View Post
Hey all
I'm replacing my friends Steering head bearings on her 2008 Gen 2. Everything has gone smoothly until I got to the races in the frame. How the hell do you get them out? There is no protruding lip to get a chisel on. Suggestions and experiences please.
Also doing her fork oil seals while I'm there. What's the best tool for hooking out the old oil seals? And what's the best weight oil to use on a standard set up? I was thinking of going a bit thicker with 15w. What would be the air gap measurement for that? I think that's enough questions for now.

Welcome to the forum UKbri!

To get the top bearing out you can use some sort of drift from the bottom, there's an edge of the bearing sticking out. The bottom one is a blind bearing Google how to remove it lots of techniques. I ended up cutting a notch in the bearing with a dremel tool to get mine out, I didn't have a torch or the bearing removal tool.

You'll have to get the forks apart to change the seals. The dampening rod's nut has to be off to pull them apart. There's a C-Clip holding the seal in, remove that and you can just pop the tubes a couple of times and the seal will pop up. Don't try to pry it out you could nick the tube. You'll need some sort of seal driver to put the seals back in, there are commercial ones but I just cut a piece of PVC pipe in half.

I put 15wt in my forks and used the same level as stock.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #6 of 7 Old 08-20-2013, 03:05 PM Thread Starter
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Welcome to the forum UKbri!
To get the top bearing out you can use some sort of drift from the bottom, there's an edge of the bearing sticking out. The bottom one is a blind bearing Google how to remove it lots of techniques. I ended up cutting a notch in the bearing with a dremel tool to get mine out, I didn't have a torch or the bearing removal tool. You'll have to get the forks apart to change the seals. The dampening rod's nut has to be off to pull them apart. There's a C-Clip holding the seal in, remove that and you can just pop the tubes a couple of times and the seal will pop up. Don't try to pry it out you could nick the tube. You'll need some sort of seal driver to put the seals back in, there are commercial ones but I just cut a piece of PVC pipe in half. I put 15wt in my forks and used the same level as stock.
Thanks Spec
That was the answer I was looking for. I wasn't worried about the top race as I could see a lip on it. I was thinking about cutting a slot in the bottom so that's confirmed my plan.
Do you need a special tool to put down the tube to undo the dampening nut or does it just unbolt from the bottom ?
What's the stock oil level ? 135mm ?
Thanks again
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post #7 of 7 Old 08-20-2013, 06:34 PM
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Thanks Spec
That was the answer I was looking for. I wasn't worried about the top race as I could see a lip on it. I was thinking about cutting a slot in the bottom so that's confirmed my plan.
Do you need a special tool to put down the tube to undo the dampening nut or does it just unbolt from the bottom ?
What's the stock oil level ? 135mm ?
Thanks again

Here's a video about the Gen 1 fork. It's basically the same for the Gen 2:



I just measured the amount of the stock oil and put the same amount of 15 wt. back in.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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