If the circlip becomes distorted during removal, replace it with a new one.
To dismantle the damper tube. Use a thin wall box key to take out bolt
(31) in the slider recess ½" across the flats, pull out the damper tube, with
damper rod assembled.
Pull out the circlip (37), extract the damper rod with valve assembled.
If the valve is taken off the rod, watch for small pin (27).
TABLE OF FORK SPRINGS USED
250 c.c. Scrambler Model and Lightweight 350 c.c.
Part No. 014950 Free length 11" Wire gauge .207"
350 c.c. Trials Model
Part No. 014950 Free length 11" Wire gauge .207"
Heavyweight Scrambler Model
Part No. 021790 (CSR) Free length 11¼" Wire gauge .222"
Part No. 016782 1962 (CS) Free length 12¾" Wire gauge .212"
Heavyweight Touring Model
Part No. 022369 Free length 11.90" Wire gauge .212"
Heavyweight Sidecar Model
Part No. 021789 Free length 12¾" Wire gauge .222"
Buffer springs.
All Models except 350 c.c. Trials
Part No. 022079 Free length 2G" Wire gauge .192"
350 c.c. Trials, 250 c.c. Scrambler and 350 c.c. Lightweight
Part No. 010360 Free length 2D" Wire gauge .187"
To remove one fork tube. If attention to one fork tube only is necessary,
the fork tube and components can be extracted by:
(1) Taking out the front wheel, mudguard and stays.
(2) Remove the domed nut (22), disconnect the damper rod and release
the Allen screw (38).
Usually the fork tube is a close fit in the two top members (39 and 41),
thus to avoid damage to the internal thread in the fork tube, a draw bolt
is required, which is also used to pull back the tube. The tools for the
large, also small, diameter fork tubes are shown in Fig. 22.
Insert the tool into the fork tube which can now be driven out.
If at this stage the slider has to be removed, and if the tube is held in
a vice, use a suitable clamp and hold the tube at the lop and away from
the oil seal travel.
Assembling the forks (without a draw bolt). Hold the fork crown in a
vice.
Assemble a fork tube with its components as described in 'Assembling
the forks with a draw bolt'.
Push the fork tube into the fork crown,
Insert the key 018667 in the Allen screw.
With one hand pull up the tube until it protrudes 6½" and quickly
tighten the Allen screw.
Then assemble the second tube in a similar manner.
Fit the crown races with bearings as previously described and pass the
fork stem through the frame.
If assistance is available hold the forks in position, assemble the top
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