Replaced steering head bearings. But......

[Falcon 269]

Tapered roller bearings in the R1 fork installation, not before.  I knew beforehand that the steering lock wouldn't line up but that's not relevant to your situation and the advice I've offered.

With correctly fitted tapered roller bearings in your bike, the steering lock would align correctly with the rubber washer in place.  I asked previously whether you did the double-torque thing to set the bearings correctly.  Did you?

[sirgalahad3]

Indeed yes, bearings set correctly.
I accept you think they are not fitted correctly, I intend to check this and accept your view.
On the other hand there does not appear to be anyone,including you,that has fitted the marksman bearings to there fazer forked fazer and can say definatly that the steering lock worked with the rubber washer in. Theory is fine,reality is a different matter INHO.
I shall report back at some stage when I have checked this out. It may be a while as I intend to ride the bike whilst the alleged summer is here.
Thank you once again for advise and help.

[sirgalahad3]

Update: ok as it was pouring down in the Black Country on Sat morning I had another look at this problem. Stripped down and checked everything,all ok. what seems to be the problem is the measurment between the bottom of the bottom adjusting nut to the top of the top locknut with the rubber washer fitted is to great to allow the top yoke to go down far enough on the stem and forks to allow the steering lock to engague. Take out the rubber washer reduces the the above measurement and all works well. The only thing that could be a problem is the condition of the rubber washer itself. It is distorted and not the round shape it should be. When fitted the top locknut can only be turned very loose finger tight before the washer is distorted even more and is squashed from between the nuts,rendering it useless.
If the washer was harder it would probably squash down with the locknut,allowing the locknut to tighten down properly,reducing the measurement between the 2 nuts and allow the steering lock to work.
I have ridden the bike to Llangollen today and it steered like a dream so all is good,washer not fitted.
I can only conclude the washer is badly perished and weak not allowing proper fitment and nut tightening.

[Falcon 269]

The washer is compressible as standard and it's job is solely to provide a means to align the locking tab slots on the adjuster nuts by taking up a little of the freeplay between upper and lower adjuster.  It is not there to provide any specific spacing between the components.  How can it when it's made of rubber?

I'll say this one last time and that's me out of it ... I suspect the lower bearing race isn't fully home in the steering head.  If I'm right, a few thousand miles of road shocks will set it properly and you'll have excessive play in the steering bearings.

[sirgalahad3]

Thats the whole point,the washer wont compress...
And my eyes tell me the lower race is fully home....
Agrees least said etc...

[Falcon 269]

I don't have the parts in front of me, obviously, but IIRC the top yoke goes down as far as a shoulder that's machined into the steering stem and no further.  That's what sets the relative positions of the yoke and the steering lock.  The chrome top nut then torques the yoke in place.

Normally the top adjuster nut is a shade below the top yoke.  However, if the stem is too low in the steering head then that nut will be too high.  With me so far?  

By removing the rubber washer, you've created space for the top adjuster to wind down further onto the lower one.  This in turn lets the yoke down onto the shoulder on the stem.  You've overcome your problem but not resolved it correctly. 

Either you have the wrong bearings (unlikely but did you keep the packaging and receipts to check against the part number listed on the Marksman site?) or it's something else.

I leave you now to figure that out. 

[sirgalahad3]

hi,unfortunatley I dont have the paperwork/packaging for the bearings any longer. The fact that the kit fits everywhere else tends to point to the fact the kit is correct as you say.
It will be interesting to see what happens when the next person comes to fit one of these kits,until then who knows!