Removing And Installing Forks

Spring fork only can be removed and replaced, or complete fork assembly (spring and rigid fork) can be removed and replaced as a unit.

Removing Spring Fork

1. Set motorcycle on rear stand.

2. Remove spring rod lock nuts (acorn-type).

3. Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod larger nuts can then be easily removed, freeing upper recoil and upper bumper springs for removal.

4. Free lower end of horn assembly from horn bracket on mudguard.

5. If motorcycle is equipped with ride control, free the two eye bolts (10) and (12) Illus. 153, from spring fork crown; if equipped with shock absorber, remove the two bolts (T), Illus. 152.

6. If motorcycle is equipped with mudguard lamp, disconnect lamp wire from terminal on ignition-light switch and tie a piece of string approximately 30" long to wire terminal. Pull wire out of loom and untie or cut string, allowing it to extend through each end of loom. String will be used when reassembling to pull wire back through loom.

7. Raise front end of motorcycle high enough to permit removing front wheel and front mudguard—support motorcycle by means of suitable blocking underneath frame.

8. Remove front wheel. See "Removing Front Wheel," Page 147.

9. Remove brake assembly from left rocker plate, after disconnecting brake shackle from rigid fork.

10. Remove front mudguard, after removing nuts and locks from rocker plate rear studs, and the two bolts securing mudguard to rigid fork.

11. Remove rocker plate studs and rocker plates assembled.

12. Remove spring fork from motorcycle.

Installing Spring Fork

13. Place buffer springs and lower cushion springs on spring rods. Apply grease to rods. Pass rods up through spring rod bushings in rigid fork bracket. Bind lower end of spring fork to lower end of rigid fork with a strap or piece of heavy wire, to prevent forks from separating while compressing cushion springs.

Note: Before installing spring fork note type of rigid fork used. Earlier type rigid fork stem upper end and fork side upper ends were on same center line, whereas, center line of later type rigid fork stem upper end is %" to rear of fork side center line.

There are three different spring forks which can be used with rigid forks as follows:

Any spring fork used with an earlier type rigid fork can be installed with either side of fork crown facing rear.

If earlier type spring fork (fork crown not milled, approximately %" wide at center lower section) is to be used with later type rigid fork it will be necessary to remove sufficient metal from one side of fork crown lower center section to allow clearance for steering damper steel disc when fork is installed.

If later type spring fork (one side of fork crown milled) is to be used with later type rigid fork, install spring fork with milled side facing rear to allow clearance for steering damper steel disc.

If latest type spring fork (fork crown not milled approximately 5/8" wide at center lower section) is to be used with later type rigid fork, spring fork can be installed either way.

14. Insert two bolts in rigid fork bracket which mount the mudguard. Place a rod about 8" long and Va" or larger diameter, on and across rigid fork brackets, resting it against the two bolts inserted in fork brackets. This rod will serve as a pry base for the leverage bar when compressing cushion springs. With a leverage bar about 18 long, anchored on top of the pry base rod and under the spring fork, lift upward to compress cushion springs sufficiently to install one of the rocker plates—then install the other rocker plate.

15. Install front mudguard.

16. Install front brake assembly on left rocker plate, and connect brake shackle to rigid fork.

17. Install front wheel.

18. Install upper bumper springs and upper recoil springs on the spring rods.

19. Remove blocking from underneath motorcycle frame.

20. Sit on mudguard to compress fork cushion (lower) springs. Tighten the two larger spring rod nuts sufficiently to provide 7/16" thread for the spring rod lock nuts (acorn-type). Install spring rod lock nuts and tighten.

21. If motorcycle is equipped with ride control, insert the two eye bolts (10) and (12) Illus. 153, through holes in spring fork crown; if equipped with shock absorber, insert the two bolts (T) Illus. 152, in spring fork crown. Install nuts and washers and tighten nuts securely.

22. Attach lower end of horn assembly to horn bracket on mudguard.

23. If motorcycle is equipped with mudguard lamp, tie string to wire terminal, pull wire through loom and connect wire to ignition-light switch terminal from which it was removed. .•>

24. After assembly has been completed, check front wheel brake for correct adjustment .

Removing Complete Fork Assembly

1. Set motorcycle on rear stand.

2. Disconnect battery negative wire at frame (ground) connection.

3. If motorcycle is equipped with spotlamps mounted on fork bracket, disconnect lamp wires and remove bracket with lamps attached.

4. If motorcycle is equipped with mudguard lamp, disconnect lamp wire from terminal on ignition-light switch and tie a piece of string approximately 30" long to wire terminal. Pull wire out of loom and untie or cut string, allowing it to extend through each end of loom. String will be used when reassembling, to pull wire back through loom.

5. Remove headlamp and disconnect its wires.

6. Disconnect all remaining wires from insulated junction terminals on horn bracket or lamp bracket, and also from horn.

7. Free cables and any wires from cable retaining clips on right and left sides.

8. Remove headlamp bracket and hom assembly.

9. Remove ride control, or shock absorber, if motorcycle is so equipped.

10. Raise front end of motorcycle high enough to permit removing front wheel and front mudguard —support motorcycle by means of suitable blocking underneath frame.

U. Remove front wheel. See "Removing Front Wheel" Page 147.

12. Remove brake assembly from left rocker plate after disconnecting brake shackle from rigid fork. Free front brake cable housing from clamp on rigid fork.

13. Remove front mudguard, after removing nuts and locks from rocker plate rear studs, and the two bolts securing mudguard to rigid fork.

14. If motorcycle is equipped with steering damper, remove lock nut from steering damper rod, then remove upper end parts in the following order: adjusting nut, keyed steel washer, fiber washer, operating lever, and actuating sleeve. This entire assembly is located in the central part of the handle bar mounting bracket. Steering damper rod, cushion spring, pressure disc, fiber disc, and steel disc alssembly can now be withdrawn (downward) from fork stem hole.

15. Remove handlebar lock nut and cone lock plate.

16. Loosen the two handlebar pinch bolts, and with a rawhide mallet, or a hammer and a block of wood, drive handlebars off fork ends. There will be enough slack in throttle and spark control wires and housings without loosening or disconnecting them when driving off handlebars. After handlebars have been driven off, swing them to left side of motorcycle and let them hang by control wire housing, placing cloth or other suitable padding as needed, to protect finish.

17. Remove upper head cone (adjusting cone) from fork stem, thereby freeing fork assembly for removal from frame head. When removing fork assembly, be careful that none of the balls in head cups drop out and become lost. Remove all balls from head cups.

Disassembling and Assembling Forks

1. Clamp fork stem in suitable vise.

2. Remove rocker plates.

3. If forks have spring rod bushing retaining plate, remove bolt from center of plate.

4. With suitable "C" clamp, decompress fork recoil springs and remove nuts from ends of spring rods.

5. Decompress cushion springs and spring fork is then free for removal.

6. Assemble forks in reverse order of disassembly. See paragraph 13, under "Installing Spring Fork,'' Page 153.

Installing Complete Fork Assembly

1. Thoroughly clean and inspect balls, cones and head cup ball races. If any are found worn or damaged, renew.

2. Put a liberal amount of Harley-Davidson grade "A" grease in each head cup and then place 17 balls in each cup. Insert fork stem through frame head and install upper head cone (adjusting cone). Adjust head cone so there is no perceptible shake in bearing; however forks must turn freely.

3. Drive handlebars onto fork ends, using a rawhide mallet, or a hammer and a block of wood.

Install cone lock plate, entering pin through hole in handlebars and engaging a notch in adjusting cone. Install and tighten handlebar nut securely. When tightening wis nut, always make sure that register on nut enters hole in lock plate and handlebars. Check steering head bearing adjustment, as tightening lock nut may have changed this adjustment slightly. The fork must turn freely without perceptible shake. If necessary to readjust, remove handlebar lock nut and cone lock plate and turn adjusting cone, clockwise for less shake or counter-clockwise if too tight. It is not necessary to remove handlebars to turn adjusting cone; cone may be turned by tapping cone at lock pin notches with a pin punch and light hammer. Cone must be adjusted so pin on cone lock plate is free to enter hole in handlebar center forging and go on through to engage a notch in the cone. Adjusting cone lock plate and lock nut must be securely tightened for each check. When desired setting is obtained, tighten handlebar pinch bolts securely.

4. Install steering damper if motorcycle is so equipped. See "Steering Damper," Page 24.

5. Install front mudguard.

6. Install front brake assembly on left rocker plate, and connect brake shackle to rigid fork.

7. Install front wheel.

8. Remove blocking from underneath motorcycle frame.

9. Install headlamp bracket with its rear connection arm below handlebar lug.

10. Install ride control or shock absorber if motorcycle is so eguipped. See Illus. 151 showing shock absorber installed.

11. Install horn assembly.

12. If motorcycle is equipped with mudguard lamp, tie string to wire terminal, pull wire through loom and connect wire to ignition-light switch terminal from which it was removed.

13. Connect headlamp wires and install headlamp.

14. Install spotlamps together with bracket if motorcycle is so equipped.

15. Connect all remaining wires that were disconnected before removing fork assembly. Refer to wiring diagram that applies as to model and electrical equipment.

16. Secure cables, and any wires orginally secured, with retaining clips, on right and left sides.

17. Secure front brake cable housing with clamp on rigid fork.

18. After assembly has been completed, check front wheel brake for correct adjustment.

Memoranda

FORK, FRAME AND HANDLEBAR ALIGNMENT

Rough Check for Fork Alignment

Obtain a perfectly straight 7/16" diameter round bar about 30" long. Turn down one end of rod to 3/8" diameter for a distance of approximately 1".

Rough check rigid fork for alignment as follows: Temporarily install a steering damper screw in fork stem upper end. Referring to IUus. 146, pass 7/16" bar through hole in fork center stem with 3/8" diameter end entering hole in steering damper screw to determine if fork sides are parallel with center stem. As shown in illustration the fork side tips should be 3-45/64" from the sides of test bar.

Upper end fork sides and fork stem must be spaced to fit handlebar mounting holes.

Fork sides can be checked for relative alignment by using two perfectly straight 5/16" diameter round bars at least 18" long. Referring to Illus. 147, note that fork is to be supported in horizontal position on level blocks or by clamping center stem in a vise. Insert one rod through holes in lower fork tips and lay the other squarely across upper end of forks. Sight across the two rods and note their relative alignment. If they are not in close alignment, either one or both of the fork sides are not straight, or possibly the fork sides are straight enough, but they are out of alignment with each other, or across the fork, due to a twist in the fork crown.

This method of checking fork alignment is recommended only in connection with emergency repair. Except in emergency, fork straightening and aligning should be referred to a shop where any needed straightening equipment and more accurate aligning gauges are available.

] SIDE VIEW STRAIGHT WITH CENTER LINE

] SIDE VIEW STRAIGHT WITH CENTER LINE

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