Topic: '71 500Four Steering Bearing Question

[armyguns]

I am continuing to chip away at restoration of a fairly complete '71 500 Four and this forum has been very helpful.  I was really hoping that reinstallation of the rebuilt forks was the light at the end of this rebuild tunnel, but I have just run into something that has me sort of stumped.  I have removed the old steering stem bearings and races.  I purchased the Rising Sun Kit (SBK-1) and without any difficulty at all (after freezing the top race) I was able to insert and full seat the TOP race into the steering tube.  This is where the problem starts.   The race is absolutely fully seated in the tube. The newly installed race sits higher in the steering tube than it should.  It is higher than the top of the tube by a full 1/8 inch.  By the time the bearing is sitting in the race, the top surface of the bearing is almost 1/4 higher than the steering tube. I know the original entire bearing was sitting just below flush with the top of the steering tube, leaving just enough room for the top dust seal.   As it sits, there is no way the dust seal will do anything and I doubt I will be able to install the steering stem.  I have double checked the 4into1 web site for compatibility of that bearing kit for my bike.  Can anyone confirm this kit actually does fit my bike, and if is does, help me out with what I am doing wrong! I can provide pictures.  If it doesn't fit, what are my options regarding getting this new race removed?  The new race outer diameter is only a couple of .001's smaller than the inner diameter of the steering tube and therefore there isn't enough of a shoulder to punch it out or use a bearing puller.  If this is not the correct kit, can you suggest a correct one? 

[HondaMan]

It sounds normal! The races for these tapered steering bearings are a little taller than the holes in the frames of these bikes. This leaves the top one always sticking out a couple of mm.

[calj737]

As Mark said, normal for tapered bearings. Realize the underside of the top clamp rides on the cage for the bearing, not the race. The dust cover will also fit because as you tighten the stem nut, the tapered bearings compress slightly.

Be dead certain to use the correct washer on the bottom before you installl your stem. Get it wrong, and that will not be coming off.

[Kelly E]

You have to measure the stack of the lower bearing including the lower bearing race, balls and dust seal. Use that measurement to determine which spacer washer to use so the new stack is the same height.
When it's wrong there's not enough threads for the top nut. If you use the wrong spacer you ruin the new lower bearing removing it to get the stack right.

[pekingduck]

When this happens, I use a fat o-ring that is a snug fit to seal out dirt, at the top, and at the bottom.