Next up is installing the Triple Tree in the Sprint Steering Head.
Again, the intent of this thread is to provide the dimensional information on what is required - I am not including specific instruction on how to remove your OEM forks and triple trees.
My premise is that you must be at least capable of this if you plan to undertake this retrofit, so I'll refrain from specifics unless there are some particular hints/tips that can be offered in the execution.
It goes without saying that some means of being able to support the front end of the bike is required, such that you are able to completely remove the triple tree. So any form of lift that relies on the forks or triples can only be an intermediate step.
If you have crash bungs this is a great support point however - lift the bike with a conventional front-end lft then lower it onto the crash bungs supported by axle stands on blocks.
It may not (likely not) be required to remove the fairings - that will come down to personal choice.
Remove the entire OEM front end - calipers/wheel/fender/bars/top clamp/fork legs/triple tree pretty much in that sequence
Then you need to remove the old bearing shells from the Triumph steering head.
Steering Head bearings.
The bottom bearing is actually the same size on all the Suzuki variants and the Triumphs - 30/55/17. The only difference is Triumph uses a tapered roller and suzuki uses ball races.
For the top bearing, on the 05+ the bearing is also the same as the Suzuki top bearing, again 30/55/17.
So to purchase new bearings for your late (05+) model install you can order bearings & dust seal kit for either the 'Busa/Tl or Sprint - will be the same parts.
For the 99-04 models, the top bearing is a different size however;
but there is a custom bearing available that has the required 30mm ID for the Suzuki stem and the 52mm OD required for the Sprint Steering head. This bearing is an NTN 4T-CR-0643 (30 x 52 x 16) which is speciality item not readily available - but is at the source mentioned following.
I recommend AllBallsBearings
for your Tapered Roller Bearings
All Balls Better Bearings & Components
Power Sport Inustries, Inc.
P.O. Box 437
822 N Reading Ave
New Berlinville, PA 19545
Ph: 610-473-0505, 888-228-3323
Fax: 610-473-8411, 888-552-0557
As aforementioned, you can easily order these on-line if you have a late model Sprint by simply specifying the Hayabusa kit - these come compete with dust seals and bearings.
For 'Busa, this is simply a 22-1003 kit on a late model Sprint
For 99-04 Sprint,
(Bearing / Dust Seal)
99-3519 / 33-1003 (30-55-17 mm)
99-3521 / 33-1005- equivelant to NTN 4T-CR-0643 (30 x 52 x 16)
This is actually available as a kit for a Yamaha model, kit # 22-1050:
Go to http://www.goallballs.com
Do a 'product look-up' on 2008 Yamaha RoadStar Warrior
Steering Bearing Kit is 22-1050.
You can buy directly on-line - the 22-1003 for late model bikes is $33 and the 22-1050 for the 99-04 is $37 (each is plus $7 shipping)
Bearing Removal from TL/'Busa Steering Stem:
This is probably the most onerous part of the whole job!
Again, particular credit to our own OldnDumb
for the procedures and pictures on removing & installing bearings:
You can use one of two methods:
One is to press the steering stem out of the bottom triple - in the action of pressing it through the bottom, it presses the bearing off the stem. One of my my good friends swaers by this method - but then he has a press in his shop!
Alternatively you have to pull the bearing from the stem in situ.
This can be aided by cutting through it with a dremel - need to be careful to not cut the stem of course!
Start by using a tapered chisel between the dust seal and bearing, working around the perimeter to start it up the stem.
I actually managed to get my 'Busa bearing off without using a puller, just using progressively bigger wedge levered under the bearing - on others I have not been that lucky!!!
Bearing Installation Tips:
1) Seat the new bearings in the steering head both top & bottom;
Use a threaded rod, long enough to extend all the way through from top to bottom,* a washer over the bearing and nut at each end; then simply tighten on the nuts to pull the bearings into the seats. This ensures that you pull them in square & also get them seated fully. Then remove the inner bearing races until ready to install the tree.
2) To press the new bearing onto the stem, use a similar technique - this time however, slip a length of conduit pipe over the stem pressing on the bearing center; again, slip the threaded rod up through the stem, place washers & nuts* and tighten down again to fully seat the bearing.
Important note: REMEMBER TO INSTALL THE DUST SEAL BEFORE PRESSING THE LOWER STEM BEARING!
One item you can use under the conduit to press the stem bearing is the old race - cut a slot in it first so it doesn't get pressed on too! (You can also see that detail in the picture above)
With the bearings on the stem & the outer shells in the steering head, you can go on & install the complete triple tree, fork legs, wheel, axle and calipers at this stage.
Follow protocols for tightening head bearinsg of course
Note that there is a washer that installs between the load nut and the lock nut of the steering stem.
That concludes the first main part of integrating your 'Busa or TL forks into your Sprint frame.