SECTION G3
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REMOVAL OF FRONT FORKS
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Removal of the front forks is most easily
achieved by dismantling in parts rather than
attempting to remove the fork assembly complete.
Pre 1971 models had the steering stem captive in
the lower yoke whereas 1971 and later models have
the stem captive in the upper yoke. This alters the
dismantling procedure for the yokes. In the case of
disc braked models, it will be found easiest to
remove the hydraulic system as an assembly, thus
relieving the necessity for refilling and bleeding
the system. Release the hydraulic pipe bracket from
the right fork slider at the fender bridge. Remove
the two bolts and spring washers securing the
caliper to the slider and lift the caliper away,
complete with pads and still attached to the brake
hose. At this stage if the brake lever is operated
accidentally, the pads and pistons will be forced
from the caliper and the fluid lost. To protect
against this, place a spacer between the brake pads
- a suitable piece of clean wood or preferably a
piece of plastic tubing would be ideal. Remove the
four crossheaded screws securing the master
cylinder to the right switch cluster, hold the
master cylinder but allow the switch cluster to
hang on its leads. Pull back the plastic switch
cover from the master cylinder and disconnect both
Lucar terminals. Release the large spring clips
securing the hydraulic hose to the right fork leg
and lift the complete hydraulic system away. The
system is sealed and can therefore be laid down
until it is to be refitted see Fig. G3. Support the
motorcycle by using a box or block of wood beneath
the lower frame rails and proceed as follows:
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1
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Remove the front wheel (see Section H5 for disc
brake wheel or Section H8 for drum braked wheel).
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2
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Unscraw and lift the fork tube large chrome top
bolts and using two spanners as shown in Fig. G7
release the damper rod from each top bolt.
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3
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Lift clear the speedometer and tachometer in
their cases and allow them to hang on the cables.
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4
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Slacken the lower lug socket headed pinch screws
(see Fig. G8).
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The fork main tubes are a tapered fit into the
upper yoke and require a shock to free them. The
shock may be delivered by grasping the fork slider
with both hands and snatching downwards several
times. If this fails to break the taper, replace
the chrome top bolt at least six threads without
the instrument case and using a block of wood to
protect the chrome finish (see Fig. G4) deliver
several blows with a hammer. This will release the
main tube from the upper yoke.
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