Do not attempt to straighten a fork tube that has a sharp angle bend. These tubes should be scrapped because the metal is stretched.

Before beginning the straightening operation, clean the fork tube. Locate bends with a dial indicator as shown in Fig. 2F-25. (A fork tube is usually bent in two or three places - seldom one place.) Then, place fork tube on straightening blocks. Using an arbor or hydraulic press, straighten tube as much as possible as shown in Fig. 2F-26.

See Fig. 2F-25. With a dial indicator find the highest point out of round and mark with chalk. Press on high point of fork tube as shown in Fig. 2F-26. Repeat pressing operations until fork tube is within .003 to .004 in. of being straight. Always check with a dial indicator after each pressing operation.

Sometimes a fork tube is out of round, especially at the point it is clamped to the fork brackets. Place tube in straightening blocks as shown in Fig. 2F-27. Press until perfectly round and check with dial indicator or micrometer. Check fork tube by inserting into a new fork slider. Work tube up and down in slider, if it does not bind, it is straight.


Straightening a fork stem and bracket assembly not only requires a great deal of practice to become proficient, but also several special tools and fixtures, including an arbor press, surface plate or suitable heavy metal plate that is perfectly smooth, bending bar, four straightening blocks (W), two improvised steel gauging bars or legs 1-5/16 in. diameter x 12 in. length (X, Fig. 2F-29), two steel support blocks (Y), and several steel press blocks (Z).

If facilities are not available locally for straightening fork stem and bracket assemblies, they may be sent

It is not necessary to disconnect clutch and brake handlevers from handlebar, wiring from ignition switch and wiring panel, or throttle and spark cables from carburetor and circuit breaker, unless handlebar assembly is to be removed from motorcycle.

Remove washer (22) and fork stem sleeve (23). Free fork stem and bracket assembly (24) and at the same time carefully remove bearing cones (25 and 26) and 28 ball bearings (27) from steering head. Inspect bearings, cones and cups for wear. If worn or pitted, replace. If necessary to remove head cups (28), insert a piece of bar stock through upper cup to drive against lower cup. Reverse operation to remove upper cup.

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