1990 Kawasaki Mojave 250 Steering Stem Bearing Replacement Guide
Shop parts for a 1990 Kawasaki Mojave 250 ATV.
The steering stem pivot on the 1990 Kawasaki Mojave 250 is a simple component that takes a complex load environment: impact loading from rough terrain, lateral forces from cornering, and constant oscillating motion under steering input. When it wears, the result is looseness, notchiness, or vague steering feel that gets progressively worse. This guide walks through the full replacement procedure from disassembly to final check.
How to Tell When the Steering Stem Pivot Has Worn Out
Worn steering stem bushing on the Mojave 250 announces itself through feel before it causes noticeable mechanical noise or visible damage. The first symptom is a change in how the bars move when the ATV is parked and the front end is lifted: instead of smooth, light resistance throughout the sweep, the bars develop a sticky or notchy quality near center.
A clunking sensation through the handlebars when riding over square-edged bumps or when applying the brakes firmly is a more advanced symptom—it indicates the steering stem is moving in the bushing under sudden load changes. To check for play directly, support the front end, grip the handlebars near the stem, and attempt to rock them laterally without turning. Any movement at the pivot point is too much.
How Steering Stem Bearings Fail Over Time
The steering stem bushing on the Mojave 250 sits at the point where all handlebar inputs translate into wheel movement, and the forces passing through it during aggressive riding are substantial. Braking forces, cornering loads, and the constant chatter from rough terrain all run through the steering stem and into the pivot point at the frame.
Moisture intrusion is the accelerant that turns a slowly degrading bushing on the Mojave 250 into one that fails ahead of schedule. The seals around the steering post housing are not a perfect barrier, particularly on older ATVs with dried-out or damaged seals. Water that enters the housing emulsifies the grease or lubricant and promotes rust and pitting on the contact surfaces. Contaminant-laden lubricant then acts as a mild abrasive during every subsequent steering input.
Gathering the Right Tools Before You Start
Before pulling the Mojave 250’s steering stem, confirm the right tools are on hand. An ATV stand or floor jack supports the front end at working height. The steering stem retaining nut is typically large-diameter and torqued firmly—check the nut size on your specific Mojave 250 and have the correct socket or wrench ready before starting.
For the Mojave 250, the steering stem pivot uses a bushing rather than a traditional bearing. You’ll need a bushing kit sized for this model—the replacement bushing and any associated seals or thrust washers. A bushing driver or a socket sized to match the bushing outer diameter is needed to drive the new bushing squarely into the housing bore without distorting it.
Removing the Handlebars and Steering Post
With the Mojave 250 on a stand and the front end elevated, begin disassembly at the handlebars. The handlebar mount bolts hold the bar assembly to the top of the steering post; remove them and set the bar assembly aside, resting it against the frame or tying it off to avoid pulling on cables. Below the handlebar mount is the steering stem retaining nut—remove any dust cap or top plate first if equipped, then remove the nut and any associated hardware.
With the stem nut off on the Mojave 250, the steering post is held in place only by the bushing and the tie rods at its base. Remove the cotter pins from the tie rod castle nuts on both sides, unscrew the castle nuts, and free the tie rod ends from the steering arm using a tie rod puller or by tapping the steering arm boss with a rubber mallet—not the rod itself.
Bearing or Bushing Removal and Inspection
Before pulling the old bushing from the Mojave 250’s frame housing, examine what came out with the post. Examine the inner bore of the bushing for ovality—a bushing that has worn egg-shaped rather than remaining round allows the post to wobble and produces the looseness felt at the handlebars.
Drive the old bushing out of the housing bore using a driver or socket sized to match the bushing’s outer diameter. Work from one end and drive it out evenly. Once removed, clean the housing bore thoroughly with contact cleaner and inspect it for scoring, raised metal, or distortion from a bushing that was running loose.
Fitting the New Steering Stem Pivot Components
New bushing installation on the Mojave 250 requires patience and the correct driver. Drive the new bushing into the Mojave 250’s housing bore using a bushing driver or socket sized to match the bushing outer diameter. The driver must contact the full face of the bushing evenly so it enters the bore squarely rather than tilting. Start the bushing by hand to confirm alignment, then drive it progressively to full depth.
Once the new bushing is seated in the Mojave 250’s housing, apply grease to the post shaft and guide the steering post back down through the housing. The post should slide through the new bushing with light resistance—smooth but not sloppy. If the fit is too tight and the post binds, confirm the bushing seated squarely and fully; a cocked bushing reduces the effective bore diameter.
Completing Reassembly and Verifying Steering Feel
Thread the stem retaining nut back onto the Mojave 250’s steering post and bring it up gradually while testing the steering feel. The correct tension removes all detectable play at the stem without introducing any resistance or binding through the bar sweep. Lock the nut in place with whatever retention method the Mojave 250 uses—a lock tab, jam nut, or cotter pin through the stem depending on design.
Reconnect both tie rod ends to the Mojave 250’s steering arm, torque the castle nuts to specification, and install new cotter pins. With both sides reassembled, lower the machine to the ground and check the steering one final time. Stand at the front, grip the bars, and sweep slowly from lock to lock. The feel should be smooth, consistent, and notably improved over the worn bushing you removed.
Related Shopping Categories
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Shop Wheel Bearings for a 1990 Kawasaki Mojave 250 ATV.
Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.