Contents: Removal the steering knuckle ↓ Checking the steering knuckle arm ↓ Replacing the bushing ↓ Installing the steering knuckle ↓
Removal the steering knuckle
1. Remove the hub and, after unscrewing the bolts, disconnect the brake assembly from the steering knuckle and hang it on a rope.
2. Disconnect the longitudinal steering rod from the steering knuckle arm.
a) Remove the cotter pin and unscrew the nut.
b) Using the special tool, disconnect the longitudinal steering rod from the steering knuckle arm.
3. Disconnect the tie rod end from the steering knuckle arm.
a) Remove the cotter pin and unscrew the nut.
b) Using the special tool, disconnect the tie rod end from the steering knuckle arm.
4. Remove the steering knuckle.
a) Remove the upper steering knuckle gasket.
b) Unscrew the nut and use a plastic hammer to knock out the pin retaining pin.
c) Using a special punch and a hammer, knock out the pin.
d) Remove the steering knuckle, washer and bearing with O-ring.
Steering knuckle (Dyna 150).
1 - Steering knuckle,
2, 7, 14 - Cotter pin,
3 - Tie rod end,
4 - O-ring seal,
5 - Upper steering knuckle gasket,
6, 9 - Bushing,
8 - Finger,
10 - Lower steering knuckle gasket,
11 - Washer,
12 - Bearing,
13 - Lock bolt,
15 - Longitudinal steering rod.
d) Remove the two O-rings from the steering knuckle and the bearing.
Checking the steering knuckle arm
Using penetrating paint, check the steering knuckle for cracks and replace if necessary.
Replacing the bushing
1. Using a punch, press out the upper and lower bushings.
2. Install the upper and lower bushings.
a) Using a drift, install the new upper bushing as shown in the figure.
b) Using a drift, install the new lower bushing so that the holes in the bushing align with the holes in the knuckle bosses.
Note: The bushings are installed with the inner surface lubricated.
c) Measure the inner diameter of the bushing.
- Inner diameter - 25.01-25.02 mm
d) If necessary, process with a special reamer.
Installing the steering knuckle
1. Install the O-rings onto the bottom of the upper bushing and bearing.
2. Install the steering knuckle.
3. Install the pin.
a) Place the hole down and the jagged side of the finger towards the hole.
b) Using a hammer, drive the pin in so that its lower edge is level with the beam.
Note: Apply grease to the bushing, bearing.
c) Install the bearing and use a feeler gauge to measure the clearance between the camshaft boss and the bearing.
- Gap - 0.10 mm or less
d) Select a washer and install it between the knuckle boss and the bearing.
- Washer thickness - 0.05; 0,10; 0.25 mm
d) Using a hammer, drive the pin in all the way.
e) Make sure the knuckle rotates freely.
g) Install the pin retaining pin and tighten the nut.
- Tightening torque - 37 Nm
4. Install the upper knuckle gasket and use a hammer to tap in the new lower knuckle gasket.
5. Connect the tie rod end to the steering knuckle arm, tighten the nut and install the cotter pin.
- Tightening torque - 152 Nm
6. Connect the longitudinal steering rod to the steering knuckle arm, tighten the nut and install the cotter pin.
- Tightening torque - 152 Nm
7. Lubricate the steering knuckle.
8. Install the brake assembly and tighten the bolts.
- Tightening torque - 127 Nm
9. Install the front wheel hub.
10. Check the front wheel alignment angles.