Suzuki 2 Strokes

I ordered a new set of tapered bearings from All Balls, the Kawi set, for myt T500 but don't know if there's
a special tool or something that I have to use to get the outer steering race off? If you asked me, I'd swear
that thing is not removeable. It's really on there! Any tips with that? Anyone replace their old ball bearings
with these tapered ones? How'd it work?

You got the All Balls 22-1012 set for the Kawi 74/78 KH400 ? Should just fit right in - and to get the old race off I found it just needed moderate persuading ..

I'm just worried that I'm going to mess up the triple tree, there's no place to get in between the race and the tree as far as prying it off or grabbing it and sliding it off. It seems like its become one with the tree... so to speak.

On the lower bearing outer race you have the stem, a bushing and the outer race itself. I found that just a gentle tap to wedge a pry between the lower edge of the race and the tree was enough to get it to move up off the bushing. The bush is a close fit to the stem, but moved up also which was convenient when I had the tree painted - I just knocked it back down when seating the new tapered race.

I did install the lower weather seal - now am looking at it again as that little bit of additional thickness (top and bottom with the two seals) means the headlamp ears may end up being a bit loose. As those bits are not back from paint yet I won't know for certain till they arrive and I have a chance to check the clearances.

Thanks so much Ian, a few timid taps with a chisel and it started coming right up. Now to
get the new one on over that bushing! I've gotta find something in here that will seat it
straight! Thanks also for the measurements on the brake stay, that's twice in one day you've
saved me!

Cheers!

Judicious use of my 4" angle grinder with a thin steel cut-off disc and the job was done in a couple of minutes.

I still have all my fingers too!

After reading a couple of different postings about using pipes and washers and heat and cold
to get the bearing on the stem I tried to figure out what I had lying around so that I wouldn't
have to make a trip to the hardware store. I didn't like the idea of using a washer because it
applied pressure to the outer rim of the bearing rather than the inner sleeve. I slept on it and
when I woke up I realized I had the perfect part. The steering column race, when turned upside
down applies pressure only on the inner sleeve while the recessed area in the original race was
just deep enough to not apply pressure on the moveable part of the bearing. Slipping this over
the bearing and then using a piece of PVC pipe and a rubber mallet did the trick! So don't throw
away those old races, they are still very useful!
It helps that it was only 12 degrees here today, so I put the steering column outside in the cold and
put the bearing on the kitchen radiator. The column shrunk just enough and the bearing expanded
just enough to slip on with the use of the race, PVC and mallet. Now on to assembly!