Continue to tighten the lower adjusting nut until no perceptible move-
ment can be felt and yet the steering head is perfectly free to turn, then
tighten down the domed nut in order to lock the adjustment.
Securely tighten the two fork crown Allen screws (this is very impor-
tant).
Remove packing from under footrest,
Special precautions: It is vitally important to firmly and positively
tighten the two Allen screws (38) which clamp the fork tubes.
Movement between the tubes and the fork crown (39) will cause
'fretting' which can weaken the tube,
Never attempt to repair a fork slider after damage by impact, by
welding. Where serious damage has occured after frontal impact, carefully
examine the slider for latent cracks,
Steering angle. When the Duplex tube frame was introduced in 1960, a
slight alteration to the steering angle was made to improve steering, also
road holding. The parts affected are the fork crown and stem and the
handlebar lug.
Whilst the difference between the old and new parts is exceedingly
small, it does affect interchange of the fork parts individually, viz., whilst
both the new type handlebar lug with fork crown can be used on early
models as a pair, they cannot be used separately.
As the new parts are virtually identical in appearance, they can be iden-
tified by the figure 6 stamped on each part.
Fitting a sidecar. To accommodate the extra load the solo fork springs
should be exchanged for a stronger type (see 'Table of fork springs'). In
the case of a heavy type sidecar, the rear suspension springs must be
changed also. Fit a steering damper to offset heavy steering and stop
handlebar wobble.
See 'Technical Data' for engine sprocket.
To re-assemble the forks (using a draw bolt). Check steering head races
for pitting or damage. Pack the lower crown race with grease and fill with
28 steel bearings, put the lower frame race over the stem to retain the
bearings. Pack the top frame race with grease, fill with 28 bearings and
place it in the frame.
Take up the fork crown and pass it through the frame, fit the handle-
bar lug and hold these two members together by fitting the nut (46).
Assemble the top cover tubes in the sequence shown in Fig, 21 and fit
them between the fork crown and handlebar lug. It may be necessary to
release the nut (46) to do this, then retighten this nut to clamp the cover
tubes. The steering head adjustment can be dealt with later.
Assembling the fork tube. With the fork tube horizontal apply a little oil
to the bottom end of the tube.
Fit the oil seal, metal backing towards the top, use a rotary motion at
the bottom end of the tube.
Fit the black bush, flange upwards, buffer spring and collar (42).
Fit one circlip, the steel bush and second circlip.
Fit from the top end, slider extension, leather washer (6).
Take up the fork slider, with damper rod assembled, pass it over the
fork tube from the bottom end, engage the slider extension.
78
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