KTM 77701999022/04 Information Seite 4

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7
4
3
6
4
Scope of supply:
1x triple clamp top (1)
8
1x triple clamp bottom (2)
1x O-ring support with sealing lip (3)
1x tapered roller bearing steering head (4)
1x O-Ring DIN3771 25x3,55 NBR 70 (5)
4x HH collar screw M8x50 10.9 (6)
4x HH collar screw M8x40 10.9 (7)
1x collar screw M8x25 10.9 (8)
5
Mounting
Prop the clean motorcycle under the frame, lifting the front wheel off the
ground. Remove the front wheel, fender, starting number holder and head-
light mask. Remove the clamp screws on the hand brake cylinder and attach
the hand brake cylinder to the left fork leg with a cable tie or similar fixing
strap to prevent the brake line from kinking. Remove the fork, handlebar mount
and upper triple clamp. Slide off the O-ring, protection ring and bearing.
Pull the lower triple clamp and steering stem out from below. Make sure no
2
dirt penetrates into the steering head.
Grease the bearing (4) (incl. bearing sleeve) in the triple clamp (e.g. with
Motorex Long Therm 2000) and assemble the vehicle in the reverse order,
using the triple clamp. Adjust the steering head support.
NOTE:
The tightening torques for screws (6), (7), and (8) are stamped onto the tri-
ple clamps.
NOTE:
Use the original steering head screw for mounting.
Checking and adjusting the steering head support
The steering head support must be checked regularly for play. To check, prop
the motorcycle under the frame, lifting the front wheel off the ground. Try
to move the fork back and forth. You should not feel any clearance. To adjust,
loosen the 5 clamp screws (7) and(8) on the upper triple clamp. Turn the
original steering head screw (10Nm) until there is no play. Never tighten the
steering head screw all the way as this will damage the bearings. Gently tap
on the upper triple clamp with a plastic hammer to avoid distortions. Tighten
the 5 clamp screws (7) and (8). Check the steering head bearing clearance
again and readjust if necessary.
The handling performance will be unsteady if there is play in the steering
head support. This could cause you to lose control of your motorcycle.
If you continue to drive with play in the steering head support, the bearings
and the bearing seats in the frame will eventually be destroyed.
The steering head bearings should be regreased at least once a year (e.g.
with Motorex Long Term 2000).
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