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Figure 2F-36. Reaming Fork Slider Bushing

Slowly start cut, turning reamer clockwise. When removing reamer after bushing is reamed, continue turning clockwise and apply a slight upward pressure to remove reamer from the finished bushing. Install the short reamer pilot, shown under 3, Fig. 2F-33, on reamer to ream the lower bushing. The Allen wrench provided with the tool set is used to tighten or loosen reamer pilots on the reamer body.

ASSEMBLING FRONT FORK SHOCK ABSORBER (Fig. 2F-24)

1967 and Earlier Models:

Assembly is essentially the reverse order of disassembly. Assemble parts on the fork piston rod (12) in the following order: Piston rod guide (11), piston collar (13), spring (14), bushing (1), and stop nut (10). Adjust stop nut (10) so that its face (B) measures .550 in. from point (A). Stake lock in four places around the center of the nut. Assemble piston valve (9), piston (8), recoil valve washer (7), piston spacer (6), valve spring (5), valve spring retainer (4) and piston rod nut (3). Using Wrench, Part No. 94691-52, turn the fork piston stop bushing (1) into the shock absorber tube (2) until the outer surface of the bushing is flush with the end of the shock absorber tube. Stake lock the threads of the bushing (1) through the small hole in the upper end of the shock absorber tube. Assemble front fork as described in "Assembling Front Fork."

1968 Models:

Assemble parts into shock absorber tube (8A) in reverse order of disassembly using Tru-arc retaining ring pliers to install rings in grooves. Assemble front fork as described in "Assembling Front Fork."

ASSEMBLING FRONT FORK (Fig. 2F-21)

1967 and Earlier Models:

Insert rod end of shock absorber (9) in fork tube (8) opposite tapered end. Place absorber and fork tube in a vertical position, absorber end screw facing up.

Assemble a new gasket (13) on end screw and dowel pin. Position fork slider (12) in place on tube end screw and turn until dowel pin registers with pin hole in slider. Assemble tube end nut and washer (11).

Turn tube assembly end for end. Pour 4-1/2 ounces of fork oil into each fork side. Insert spring (10) in fork tube (8). Using a brake rod or appropriate rod with a 5/16 x 24 thread, screw into threads of absorber rod end. Compress the spring and grip flats of absorber rod with vise grip pliers. Remove brake rod and turn piston rod retainer (7) into the end of the absorber rod. Stake lock the threads of retainer (7) through the small hole located near the top and on the flat side of the absorber rod. Using Wrench, Part No. 94694-52, install the piston rod retainer (7) into the fork tube (8). The top of retainer should measure 9/16 in. down from top of fork tube.

1968 Models:

Assemble slider (12) on fork tube and shock absorber assembly (8A). Use new o-ring (13A). Insert screwdriver or rod into upper end of fork tube to hold slotted end of tube (8A) while tightening bolt and washer (11A). Insert spring into fork side and pour 4-1/2 ounces of fork oil into each fork side. Using wrench, Part No. 94694-52, install spring retainer (7A) into fork tube. The top of the retainer should measure exactly 3/4 inch down from top of fork tube.

Install assembled fork side (6) into mounting brackets. Securely tighten fork tube cap (1) before tightening the fork tube pinch bolt. Secure fork boot in lip of retainer (15). Install front fender and headlamp housing. Install front wheel and brake assembly as described in "Removing and Installing Front Wheel," Section 2C.

INSTALLING STEM AND BRACKET ASSEMBLY, AND FORK SIDES (Fig. 2F-21)

Assembly of the fork stem and bracket assembly is essentially the reverse order of disassembly. Assemble the head cups (28), ball bearings (27) and bearing cones (25 and 26). Apply a heavy coating of grease to the bearings when positioned in head cups. Install the fork stem (24) and tighten fork stem sleeve (23) on fork stem until all appreciable play is taken up and bearing action is smooth and free. Assemble spacer (22), handlebar assembly and upper fork bracket (21).

Install fork sides (6) after assembly into mounting brackets. Securely tighten fork tube cap (1) before tightening fork tube pinch bolts. Secure fork boot in

Figure 2F-37. 1966 & Earlier Rear Shock Absorber - Exploded View

Cover clamp with screw and nut Top Cover Stud cover (1965) Mounting stud nut (2) Mounting stud plain washer (2) (1964) Cup washer (2) (1965) Stud rubber bushing (4) Cam Support Bumper Cover Spring Lower cam

Spring rotating cam (1964) Rotating cam (1965 & later) Cam sleeve Dirt seal

Spacer washer (3 std.) Shock absorber Roll pin

Figure following name of part indicates quantity necessary for one complete assembly.

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