SECTION G8
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REFITTING FRONT FORKS
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Reassembly of the front forks is virtually a
reversal of the dismantling procedure though for
clarity, the full 5 procedure is detailed below:
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1971 and later models
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1
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Place the top dust caver and washer over the top
steering head bearing. Note that the washer fits
below the cover.
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2
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Pass the stem of the upper yoke through the
bearings. This will almost certainly require the
use of a block of wood and a hammer to tap the stem
fully home.
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3
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Lift the headlamp and top covers roughly into
position, place the single 'O' ring in each side of
. the upper yoke to locate the tops of the fork
covers. Use heavy grease to hold the 'O' rings in
place.
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4
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Place the lower yoke, with two 'O' rings to
locate each fork cover, over the steering stem. Fit
the tab washer and nut to the stem and commence to
tighten. As the lower yoke is raised, locate the
top covers, both top and bottom.
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5
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Tighten the nut sufficiently to pull the lower
yoke into position, but do not secure fully yet.
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1970 Models
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1A
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Pass the stem of the bottom yoke up through the
bearings.
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2A
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Place the top bearing dust cover over the stem.
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3A
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Fit the fork stem nut and tighten down to pull
the stem fully home through the bearings. Since the
bearings are adjustable, tighten the nut to
eliminate any shake between the stem and steering
head but not sufficient for the bearings to bind as
the yokes are turned lock to lock.
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4A
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On Fastback models only, place both top shrouds
with headlamp brackets loosely in position,
complete with top rubbers.
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5A
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Place the top yoke over the stem and loose
assemble with the large stem washer and large blind
chrome stem nut.
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6A
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Before procceding to operation 6 "All Commando,"
ensure that the assembled spring cover tubes are in
position.
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All Commando models
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6
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Offer both fork legs through the lower and upper
yoke and pull the main tube tapers into the upper
yoke using the instrument cases and large chrome
top bolts.
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7
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With the fork legs secured by the top bolts,
snug the socket headed pinch screws.
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8
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Now tighten the fork securing points shown in
Fig G8/9 in this sequence: Chrome top bolts, main
fork stem nut, lower yoke pinch screws. Note that
the stem nut must not be over-tightened. On 1970
models this wouid damage the steering head
bearings, which must adjust until the forks are
free to turn with no perceptible play.
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