Support the tube in 'V' blocks and use an Arbour press.
NOTE—The fork tubes must be smooth and free from bruises and
blemish, particularly in the part where the oil seal operates, otherwise
the seal will be damaged beyond further use, with serious oil leakage.
Fork damper conversion (Scrambler Models). For the 1962 season an
improved type of fork damping was introduced in the Heavyweight forks
fitted to Scrambler Models.
Earlier type forks can be converted by:
Dismantling the forks.
Dismantling the damper tubes (34).
Seal off, by welding, the small hole below the slot for the circlip (37).
Drill a
z" diameter hole 2" from the top of the damper tube.
Drill a W" diameter hole 3" from the top of the damper tube.
Reduce the overall length of the top cover tube (16) to 1 z".
Reduce the overall length of the slider extension (7) to 3d".
Use fork springs 016782.
Discard the buffer springs (10).
Fit two gaiters (dust protectors).
Fit four gaiter clips 042775.
If new parts are required, instead of converting use:
2 Bottom cover tubes
028046
2 Slider extensions 028051
2 Damper tubes 028048
2 Main springs 016782
2 Gaiters 020463
4 Gaiter clips 042775
Removing the front forks. Remove the two drain plugs (56) in turn and
catch oil in a container.
Raise the front wheel with boxes under footrests.
Remove handlebars (use padding on the petrol tank to avoid damage),
Remove head lamp and disconnect speedo drive cable.
Remove front wheel, mudguard and stay.
Remove steering damper plate to frame (if fitted).
Remove rubber grummets from tube bolts (22), also the two bolts. Use
spanner 018667.
Remove lock nuts (24) and adaptor to release damper rods (25).
Remove domed nut (45) and adjusting nut (46).
Tap off the handlebar lug (41) using a rawhide mallet, until the lug
clears the fork stem (40) and tubes, the forks can then be taken away as
a unit, Watch for steering race ball bearings, 56 in number.
Dismantling the forks. Hold the fork stem in a vice.
Remove slider extension (7) from the slider (15) by unscrewing from
the slider.
Remove slider by giving it a sharp jerk downwards. The oil seal is a
close fit in the top of the slider. If there is resistance in separating the
slider, apply a little heat 1o the top part, which will expand and enable
the slider to come away with ease, with the damper assembly attached,
Remove two Allen screws (38) then pull out the fork tubes.
To remove steel bush. Prise out the circlip (12) and pull off the bush.
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