Has anyone got a diagram of how the headstock bearing sits? Can't seem to get the protective rubber around the lip of frame on top of bearing locator. Thanks
Page 14-10 of the shop manual you can get on this site shows two diagrams which may help.
Looking at the pics, it's not clear to me that the outer edge of the cap needs to meet the frame. The oil seal is inside of that -- I think it's probably just meant to direct water away from that area rather than seal it.
•Install the steering stem [A] through the head pipe and
install the upper bearing [B] and inner race [C] on it.
Stem Cap [D]
Steering Stem Nut [E]
• Settle the bearings in place as follows.
○Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41
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)
•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
• 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 temporary tighten the stem head
•Install the front forks (see Front Fork Installation in the