them along the fork tube and take off from the top end past the taper
end, if the oil seal is to be used again.
Assembling the forks. It will be apparent from the dismantling instruc-
tions given that there is nothing complicated in the fork assembly and if
the reverse sequence is used, no difficulty should occur with the following
precautions.
The fork tube, where the oil seal operates, must have a smooth finish
and free from blemish.
The oil seal is fitted from the top of the tube, with the visible spring
facing downwards against the flange for the bush.
The damper tube cap also the damper tube fixing bolt must be properly
tightened.
Finally tighten the bottom cover (23) when the front wheel has been
put back.
Fill 5 ozs. of S.A.E. 20 oil to each fork leg.
Front Forks 250 c.c. Model
An exploded view of the front forks, is shown in Fig. 23.
Dismantling the forks. Remove the front wheel as described in 'Wheels
and brakes' section.
Take off the head lamp front and detach bulb holders.
Disconnect the speedometer drive cable.
Detach the black and blue cable plugs.
Detach ammeter wires and dip switch cable.
Detach handlebars.
Detach front mudguard by taking out the two clip bolts, expand the
clip a trifle to avoid damage to enamel.
Detach drain plugs (7) and catch the oil.
Detach head stem nut (24), watch for three shim washers.
Detach steering head stem and support the forks. Watch for head bear-
ings (29), set of 39 and take away forks. Support the forks in a vice, take
out screw (2), and pull off the bottom slider extension (13) with fork
spring attached.
Detach two screws securing top cover tube, and take tube away.
Detach bolt (15), pull out fork spring and damper. The spring is
screwed on to the damper, also the top spring anchor.
Removing the oil seal.
The oil seal will come away attached to the slider.
Secure the slider in a suitable clamp fixed in a vice.
Bring the mudguard clip up to the oil seal body, using a series of light
blows with a hammer directed on to the ears of the clip. Move the clip
round the seal body whilst doing this to remove it squarely.
Re-assembling the front forks.
The work involved is straightforward with
the following precautions:
(1) After fitting the cover tubes leave the two fixing screws loose. When
the forks are assembled and working correctly, retighten the screws.
(2) Assemble the oil seal to the slider squarely.
(3) When refitting the slider bring the seal up to the bush. Use a small
radio-type screwdriver or similar tool, insert the tool between the oil seal
rubber and the fork bush. Use a rotary motion pressing gently against the
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