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Fork and Frame Service
STEERING HEAD ADJUSTMENT
With the machine on the stand, need for adjustment of the steering head bearings may
be detected by trying to rock the forks with hands holding the fork legs,
should be tested for slackness after the first 200 miles and subsequently every 1,000 miles.
Two spanners should be used, one turning the adjusting nut (34) the other to slacken and
retighten the lock nut when the adjustment has been carried out.
Adjustment should be such that no play be felt, yet the bearings are free to rotate and
are not over tight.
Adjusting the bearings too tightly will ruin them, and induce heavy steering.
NOTE.—It is important that adjusting and locking nuts are tightly locked together.
FRONT FORKS
The construction of the forks is clearly illustrated in the exploded drawing, and it will be
noted that the structure comprises of two main tubes with fixed externa) bearings, and
welded up crown and top pressings.
and to damper posts fitted at the lower ends of the slider tubes,
As the fork slider and damper tube move upwards against the resistance of the main
spring, oil is forced up through the annular clearance between the damper tube and the
slider leg. Because the damper tube is tapered, the clearance diminishes progressively,
resulting in increased hydraulic resistance to upward movement of the fork slider,
When the maximum diameter of the damper post enters the end of the tube, the oil
flow is restricted, thus providing a hydraulic lock which prevents "fork bottoming".
FRONT FORK MAINTENANCE
The forks are self lubricating and normally require no attention beyond changing the oil
every 5,000 miles.
The oil should be drained by removing plugs (7).
After the fork legs have drained, the drain plugs and washers should be replaced. With
the machine on the stand, remove the filler Plugs (2) and refill each leg with 70 ccs.
of SAE 30 oil.
Since 30 ccs. of oil will remain trapped in the damper plugs after draining, the addition
of the above mentioned 70 cc. of oil will give the correct 100 ccs. of oil in each leg,
After refilling, the machine should be rolled off the stand to locate the top spring adaptors
and to replace the top filler plugs and washers.
TO REMOVE T H E COMPLETE FRONT FORK ASSEMBLY
Owners are advised not to interfere with the forks unless absolutely necessary,
fork has been damaged, it is best to remove it complete and obtain a service exchange unit.
To remove the fork assembly follow this sequence:—
Place the machine on the centre stand and remove the front wheel and mudguard.
Remove the battery, headlamp shell speedometer cable, reflector unit, ignition warning
light, ammeter leads, lighting and ignition sockets. Disconnect the control cables and the
two wires from the dip switch harness to the main harness.
Remove steering column top nut (24) and withdraw column itself (26) from the bottom
whilst holding the fork in position. The fork unit can be taken away after removal of
distance piece and washer (watch for 34 ball bearings).
If it is desired to dismantle the slider units, the fork sliders complete with oil seals and
springs may be withdrawn after removing top filler plug screws.
Care should be taken not to damage the oil seals when pulling them over the bearings.
TO REFIT T H E FORKS AS A U N I T
Reassemble in reverse sequence,
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250 c.c. Models G2 and G2S
Long coil springs are attached to the top pressing
30
30
The bearings
If the
Remove the handlebar.
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