Rocker Arms (see Rocker Arm Removal)
Swingarm (see Swingarm Removal)
Sleeves [A]
Grease Seals [B]
Remove the needle bearings [C], using a suitable tool.

SUSPENSION 13-37
Tie-Rod, Rocker Arm
Tie-Rod and Rocker Arm Bearing Installation

the needle bearings and grease seals with new
• Replace
ones.
grease to the lips of the grease seals.
• Apply
Install
• shown.the needle bearings and grease seals position as

○Screw the needle bearing driver into the driver holder.
○Insert the needle bearing driver into the needle bearing
and press the needle bearing.

NOTE

○For a bearing of inner diameter

18, select the pressing
side of the needle bearing driver according to its pressing depth.

Special Tools - Bearing Driver Set: 57001-1129
Needle Bearing Driver,
17/ 18:
-1609

○Install

57001

NOTE

the needle bearings so that the marked side
faces outward.

Needle Bearings [A]
Grease Seals [B]
Frame [C]
Rear Shock Absorber [D]
Swingarm [E]
Tie-Rod [F]
Rocker Arms [G]
5.0 mm (0.20 in.) [H]
Front [I]
Right Side [J]
Left Side [K]

13-38 SUSPENSION
Tie-Rod, Rocker Arm
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
inspect the rocker arm, or tie-rod sleeves [A] and
• Visually
needle bearings [B].
rollers in a needle bearing normally wear very little,
• The
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve and needle
bearings as a set.

Rocker Arm/Tie-Rod Bearing Lubrication
NOTE

○Since the bearings are packed with grease, lubrication
is not required.

STEERING 14-1

Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Steering ..................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Electronic Steering Damper (ESD).........................................................................................
Electronic Steering Damper Removal...............................................................................
Electronic Steering Damper Installation............................................................................
Electronic Steering Damper Oil Leak Inspection ..............................................................
ESD ECU Removal...........................................................................................................
ESD ECU Installation........................................................................................................
Steering Stem.........................................................................................................................
Stem, Stem Bearing Removal...........................................................................................
Stem, Stem Bearing Installation........................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Steering Stem Warp Inspection ........................................................................................
Stem Cap Deterioration, Damage Inspection ...................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................

14-2
14-4
14-5
14-5
14-5
14-6
14-6
14-6
14-7
14-7
14-7
14-9
14-9
14-10
14-12
14-13
14-13
14-14
14-14
14-15

14

14-2 STEERING
Exploded View

STEERING 14-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11

Fastener
Switch Housing Screws
Front Fork Clamp Bolts (Upper)
Steering Stem Head Nut
Handlebar Clamp Bolts
Throttle Case Bolts
Handlebar Positioning Bolts
Steering Damper Mounting Bolts
Handlebar End Bolts
Steering Stem Nut
Front Fork Clamp Bolts (Lower)
Steering Damper Bracket Bolts

N·m
3.5
20
80
25
3.5
10
11
25
20
23
8.0

Torque
kgf·m
0.36
2.0
8.2
2.5
0.36
1.0
1.1
2.5
2.0
2.3
0.82

ft·lb
31 in·lb
15
59
18
31 in·lb
89 in·lb
97 in·lb
18
15
17
71 in·lb

Remarks

AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
S: Follow the specified tightening sequence.

S

L
L
L
AL
S

14-4 STEERING
Special Tools
Bearing Puller:
57001-135

Steering Stem Bearing Driver,
57001-1344

Head Pipe Outer Race Press Shaft:
57001-1075

Steering Stem Bearing Driver Adapter,
57001-1345

Steering Stem Nut Wrench:
57001-1100

Head Pipe Outer Race Driver,
57001-1446

Bearing Driver Set:
57001-1129

42.5:

55:

41.5:

STEERING 14-5
Steering
Steering Inspection

to the Steering Play Inspection in the Periodic Main• Refer
tenance chapter.

Steering Adjustment

to the Steering Play Adjustment in the Periodic
• Refer
Maintenance chapter.

14-6 STEERING
Electronic Steering Damper (ESD)
Electronic Steering Damper Removal

• Remove:
Clamp [A]
Disconnect:
• Connector [B]
• Remove:
Steering Damper Mounting Bolts (TORX Bolts) [C]
Washer [D]
Washer and Collar [E]
Electronic Steering Damper [F]

Electronic Steering Damper Installation

ZX1000S/Z, fit the brake pipes [A] onto the grooves
• For
of the lower bracket [B].
the upper bracket [C] onto the lower bracket.
• Fit
Install
bracket bolt (left side) [D] and tighten it loosely.
• Rear the
Side View [E]

the bracket bolt (right side) [A] and tighten the
• Install
bracket bolts following the specified tightening sequence
temporarily.
Tightening Sequence:
[A → B → A]

the bracket bolts with the specified torque by the
• Tighten
same sequence.
Torque - Steering Damper Bracket Bolts: 8.0 N·m (0.82
kgf·m, 71 in·lb)

the following parts as shown.
• Install
Collar [A]

•
•

Washer (t = 3.5 mm, 0.14 in.) [B]
Electronic Steering Damper [C]
Washer (t = 1.2 mm, 0.047 in.) [D]
Apply a non-permanent locking agent to the threads of
the steering damper mounting bolts (TORX bolts) [E].
Tighten:
Torque - Steering Damper Mounting Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)

STEERING 14-7
Electronic Steering Damper (ESD)
tightening the steering damper mounting bolts, con• After
firm that there is play [A] in the steering damper [B].
Left Side View [C]

sure to run the main harness under the steering
• Be
damper bracket [A].

○In this photo, the fuel tank covers have been removed for

clarity.
Hold the main harness with the clamp [B].
○Fit the projection of the clamp to the hole in front of the
electronic steering damper.
Connect the connector [C].

•
•

Electronic Steering Damper Oil Leak Inspection

to the Electronic Steering Damper Oil Leak Inspec• Refer
tion in the Periodic Maintenance chapter.

ESD ECU Removal
NOTICE
Never drop the ECU especially on a hard surface.
Such a shock to the ECU can damage it.
up the front portion of the fuel tank, and hold it with a
• Lift
suitable bar or block (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

NOTE

○When removing the ESD ECU only, there is no need to
lift up the fuel tank.
the ESD ECU [A] with the rubber protector.
• Remove
Disconnect
the ESD ECU connector [B].
•

ESD ECU Installation

• Install the ESD ECU [A] in the rubber protector [B].

14-8 STEERING
Electronic Steering Damper (ESD)
the ESD ECU connector.
• Connect
Install
the
ESD ECU on the bracket.
•○Insert the slot
[A] of the rubber protector into the projection

•

[B] of the bracket.
Install the removed parts (see appropriate chapters).

STEERING 14-9
Steering Stem
Stem, Stem Bearing Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Steering Stem Head with Handlebars (see Handlebar
Removal)
Front Forks (see Front Fork Removal in the Suspension
chapter)
Brake Hose Fitting Bolt (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter)
the claws [A] of the claw washer straight.
• Bend
Remove
the steering stem locknut [B].
•
Special Tool - Steering Stem Nut Wrench: 57001-1100

• Remove the claw washer.

up the stem base [A], and remove the steering
• Pushing
stem nut [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100

• Remove:
Steering Stem
Stem Cap [D]
Upper Ball Bearing Inner Race and Ball Bearing
Screws [E] (Both Sides)
remove the collars [A] with ball bearing outer races
• To
pressed into the head pipe [B], insert a bar [C] into the
head pipe and apply it on the recesses of the collar, then
hammer the bar on both recess alternately to drive the
races out.

NOTE

○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.

14-10 STEERING
Steering Stem

• Remove the lower ball bearing [A] from the steering stem.

the lower bearing inner race (with its grease seal)
• Remove
[A] which is pressed onto the steering stem [B] with the
bearing puller [C] and adapter [D].
Special Tool - Bearing Puller: 57001-135

Stem, Stem Bearing Installation

the collars and bearing outer races with new
• Replace
ones.
the bearing outer race [A] in the collar [B] until it is
• Press
bottomed.
Special Tool - Bearing Driver Set [C]: 57001-1129

• Drive the collars into the head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 55 [B]: 57001
-1446
or Bearing Driver Set: 57001-1129

grease to the outer races.
• Apply
Tighten
the screws.
•
the bearing inner races and oil seal with new
• Replace
ones.
grease to the oil seal.
• Apply
Install
the oil seal [A] on the steering stem, and drive the
• lower ball
bearing inner race [B] applied the grease onto
the stem.
Special Tools - Steering Stem Bearing Driver, 42.5 [C]:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [D]: 57001-1345

STEERING 14-11
Steering Stem
grease to the lower ball bearing [A], and install it
• Apply
onto the steering stem.

○The lower and upper ball bearings are identical.

grease to the upper ball bearing [B] and inner race
• Apply
[C].

the steering stem [A] through the head pipe and
• Install
install the upper bearing [B] and inner race [C] on it.
• Install:
Stem Cap [D]
Steering Stem Nut [E]

the bearings in place as follows.
•○Settle
Tighten the steering stem nut with 65 N·m (6.6 kgf·m, 48
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 steering stem nut wrench [A].
○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: 20 N·m (2.0 kgf·m, 15 ft·lb)

the claw washer [A] so that its bent claws [B] faces
• Install
upward, and engage the bent claws with the grooves of

•
•

steering stem locknut [C].
Hand tighten the steering stem locknut until it contacts
against the claw washer.
Check if the straight claws [D] of the claw washer aligned
with the grooves of the steering stem nut [E].

In case of the claws positioned between the grooves:
Tighten the steering stem locknut [A] until the straight
claws aligned with 3rd grooves [B] of the steering stem
nut [C].
○Count the number of groove from the first aligned groove
[D] as shown.
Bend the two straight claws downward into the groove of
the steering stem nut.

•
•

14-12 STEERING
Steering Stem
In case of the claws aligned with the grooves:
Tighten the steering stem locknut [A] until the straight
claws aligned with 3rd grooves [B] of the steering stem
nut [C].
○Count the number of groove from the next aligned groove
[D] as shown.
Bend the two straight claws downward into the groove of
the steering stem nut.

•
•

the stem head.
• Install
Install
• nut. the washer, and temporary tighten the stem head
the front forks (see Front Fork Installation in the
• Install
Suspension chapter).

NOTE

○Tighten the front fork clamp bolts (upper) first, next the
stem head nut, last the front fork clamp bolts (lower).
○Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
Torque - Front Fork Clamp Bolts
kgf·m, 15 ft·lb)
Steering Stem Head Nut:
ft·lb)
Front Fork Clamp Bolts
kgf·m, 17 ft·lb)
Handlebar Clamp Bolts:
ft·lb)

(Upper): 20 N·m (2.0
80 N·m (8.2 kgf·m, 59
(Lower): 23 N·m (2.3
25 N·m (2.5 kgf·m, 18

WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables, harnesses and hoses are routed
properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Adjust
steering (see Steering Play Adjustment in the
• PeriodictheMaintenance
chapter).

Steering Stem Bearing Lubrication

to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.

STEERING 14-13
Steering Stem
Steering Stem Warp Inspection

the steering stem is removed, or if the steering
• Whenever
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.

Stem Cap Deterioration, Damage Inspection
Replace the stem cap if its oil seal [A] shows damage.

14-14 STEERING
Handlebar