[gronk62]

At the risk of copping some ridicule from more knowledgable members I've decided to post a little "how too" for servicing the head stem bearings.

I'm not suggesting this is the correct way. Its is simply how I do it.

I have to replace my front tyre this week so while I've got the front wheel off I decided it was a good time to top my fork oil up to the correct level and grease the bearings as the front end of the bike is already half disassembled.

First I put my bike up on the stand so the front wheel is off the ground.

Next I removed the front fender.

Then I removed the brake caliper. Those funny bolts on the 04's caliper are 10mm although I don't know the correct name for the heads coz they ain't hex and have 12 points.

I undid the allen bolt that holds the brake hose in position under the lower fork yoke and let the caliper hang on the hose.

Next I removed the forks.

This pic shows how I supported the handlebars and top fork yoke with all cables still attached.



(It also shows another bungee I used to hold the lower yoke and stem in place while I installed the top bearing after cleaning and greasing.)

The next step was to remove the stem bolt and at this point its important to have your tank well protected against accidental slips with the ratchet.
I use a thick towel and a sheep skin.

Next loosen the pinch bolt holding the fork stem and the lower yoke and stem will just slide right out the bottom.

These pics show the condition of the bearings after 25,000km's (15,500miles).
I know the service schedule says to this job at 16,000km (10,000mile) intervals but I decided to wait till I needed to change the front tyre.
There is still plenty of grease on the bearings to lube them and I have never found the need to service these bearings on any of my bikes more often than 25,000km intervals.





Once I cleaned and repacked 'em with fresh wheel bearing grease its just a simple matter of reassembling everything and adjusting the tension on the bearing using the "Fall away" method.
I won't go into all the details here as its a lot of typing but basically you adjust the the fork stem bolt untill the front end flops to one side or the other with no more than a cuppla inches gentle nudging.
If its too tight your bike will feel weird goin' into corners.
If its too loose one of the symptoms will be tank slappers over rough surfaces (ask me how I know )

Note: While the forks were off I removed the caps and springs and topped them up to the correct level which is "spring removed, fully compressed" and the oil level should be 146mm (5.75") from the top.
This is a service literature update listed in HD service bulletin M-1158 and applies to 04 - 06 Sportsters.