98. FORKS (figs. 63 and 64).

a. Either the spring fork can be removed and replaced, or the complete fork assembly (spring fork and rigid) can be replaced.

b. Remove Spring Fork (fig. 63).

(1) Support vehicle on rear stand.

(2) Remove the fork spring rod lock nuts (acorn‐type).

(3) Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod large nuts can then be easily removed, freeing the upper recoil and upper bumper springs for removal.

(4) Remove front wheel (par. 125).

(5) Remove front mudguard (par. 104).

(6) Remove spring fork right and left side rocker plate studs. NOTE: Leave rigid fork rocker studs, with rockers, attached.

(7) Remove spring fork from vehicle.

c. Install Spring Fork.

(1) Place buffer springs and lower cushion springs on fork rods. Apply grease to rods. Pass fork rods up through rigid fork bracket. Bind lower end of spring fork to lower end of rigid fork with a strap or piece of heavy wire (fig. 64), to prevent forks from separating while compressing cushion springs.

(2) Install two bolts in the rigid fork brackets which mount the mudguard; then place a rod about 8 inches long on the brackets to provide a pry base for the leverage bar when compressing cushion springs (fig. 64). With a leverage bar about 18 inches long, anchored on top of the pry base rod and under the spring fork, lift upward to compress cushion springs sufficiently to install one of the rocker plates. Then install the other rocker plate (fig. 64). NOTE: Left side spring fork rocker plate stud has a button end which fits into notch in brake stabilizer plate.

(3) Install mudguard (par. 104).

(4) Install front wheel (par. 125).

(5) Install the two spring rod bushings. Install upper bumper springs and upper recoil springs on the fork rods, applying grease to rods.

(6) Remove blocks from under vehicle.

(7) Sit on mudguard to compress fork cushion (lower) springs. Tighten the two large spring rod nuts sufficiently to provide full thread for the spring rod lock nuts (acorn‐type). Install spring rod lock nuts and tighten.

(8) See that all nuts, bolts, and screws securing lamp bracket, mudguard, scabbard carrier, and ammunition carrier are tightened securely.

(9) Check front wheel brake for operation.

d. Remove Upper Recoil Springs and/or Upper Bumper Springs.

(1) Support vehicle on rear stand. Remove the fork spring rod lock nuts (acorn‐type).

(2) Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod large nuts can then be easily removed, freeing the upper recoil and upper bumper springs for removal.

e. Install Upper Recoil Springs and/or Upper Bumper Springs.

(1) Apply grease to fork spring rods and install upper bumper springs.

(2) Install upper recoil springs over bumper springs on fork spring rods.

(3) Sit on front mudguard to compress cushion (lower) springs sufficiently to start on spring rod large nuts.

(4) Tighten both spring rod large nuts. Install and tighten the two spring rod (acorn‐type) lock nuts.

f. Remove and Install Lower Cushion Springs and/or Lower Buffer Springs. This operation calls for same procedure followed in removing and installing spring fork (steps b and c above).

g. Remove Complete Fork Assembly.

(1) Remove ammunition box carrier (par. 103).

(2) Remove scabbard carrier (par. 103).

(3) Remove front wheel (par. 125).

(4) Remove steering damper (par. 99).

(5) Remove front mudguard, after removing nuts and locks from rear rocker plate studs, two screws and nuts securing mudguard to rigid fork, and the two bolts mounting headlight bracket to mudguard. NOTE: Front mudguard blackout light wire connects to ignition and light switch and care must be exercised not to break this wire if it is not disconnected from the switch.

(6) Disconnect battery negative ground wire at frame connection. Remove blackout light (par. 114). Remove headlight, horn, and bracket assembly as one unit.

(7) Remove handle bar brake fittings and brake control wire housing from side of fork. Remove handle bars after removing handle bar bracket lock nut and cone lock plate. It is not necessary to disconnect spark and throttle control wire housings from frame. Unscrew fork upper adjusting cone from fork stem, freeing fork assembly to be removed from frame head. NOTE: Steering head ball bearings are loose (not in retainers) in upper and lower frame head bearing cups. Take care not to lose balls.

h. Install Fork Assembly. With vehicle on rear stand, and front end up by blocking under frame loop or skid plate, proceed with installing fork assembly, as follows:

(1) Thoroughly clean upper and lower frame head bearing cups and pack with general purpose grease No. 2, installing fifteen ⁵⁄₁₆–inch ball bearings in each cup. Work grease thoroughly in between balls.

(2) See that lower fork stem cone is clean and in place, pass fork stem up through frame head, turning on upper adjusting cone. Do not try to adjust bearing cone as yet.

(3) Install handle bars by locating mounting bracket on ends of fork sides and center stem, making sure that spark and throttle control wire housings are in place.

(4) Adjust upper fork stem adjusting cone so that there is no perceptible shake in head bearings when handle bars are worked up and down, and fork does not bind when turned to right and left extremes.

(5) Install cone lock plate by engaging pin in one of the cone notches.

(6) Install lock nut on stem and tighten securely. NOTE: Check head bearing play, as tightening lock nut sometimes makes head bearing too tight. Readjust if necessary.

(7) Attach handle bar brake fittings and brake control wire housing to side of fork.

(8) Reinstall headlight, horn, and bracket assembly. Connect wires (per wiring diagram fig. 73) before front mudguard is reinstalled. Install blackout light (par. 114). Reconnect battery negative ground wire to frame ground connection.

(9) Install steering damper (par. 99).

(10) Install front mudguard. Attach two screws, washers, and nuts for rigid fork mounting and two bolts, washers, and nuts for headlight bracket mounting. Fit right and left mudguard brace clip locks to right and left side rocker plate studs respectively. Do not put on nuts until after installing ammunition box carrier and scabbard carrier.

(11) Install front wheel (par. 125).

(12) Install scabbard carrier and ammunition box carrier (par. 103).

(13) Check lights, horn, spark control, throttle control, front brake control, steering damper control, and steering head bearing for freedom without binding.

i. Remove Rocker Plate Studs. Studs and/or rocker plates can be removed and installed in the same operation. In removing and installing studs, remove only one fork rocker plate at a time, leaving the other plate attached to opposite side fork ends to hold fork springs in compressed position. This will eliminate necessity of compressing fork springs to fit rocker plates on studs.

(1) Remove front wheel (par. 125).

(2) Remove nuts and locks from rocker plate studs on right side of vehicle. This releases gun scabbard carrier and mudguard stay clip. NOTE: Remove the large nut which secures the long stud to rigid fork.

(3) Drive out studs from fork ends, releasing rocker plate.

(4) Install studs and rocker plate before removing studs from left side of vehicle.

j. Install Rocker Plate Studs. Apply grease to studs and insert in rocker plate, then install large flat washers on studs before mounting this assembly on fork ends. Make sure that short stud is in front position, and that long stud is in rear position for the rigid fork.

(1) Drift studs (with plate assembly) into fork end holes from the inside.

(2) Install special nut lock (with half round hole) on front stud and turn stud as necessary to make lock “cup” over end of fork. Install and tighten stud nut and bend up end of lock for security. Place lock washer over long stud and install thick nut, securely tightening it.

(3) Attach end of gun scabbard carrier and mudguard brace clip with special lock to long stud, replacing washer and nut.

(4) After right side rocker plate and/or studs have been installed, remove and install studs and/or plate on left side of vehicle following same step‐by‐step procedure as above. The exceptions will be ammunition box carrier instead of scabbard carrier; also, the left side front stud is special, having a “button” end.

(5) Install front wheel (par. 125).

99. STEERING DAMPER (fig. 65).

a. Remove (fig. 65).

(1) Remove front wheel (par. 125).

(2) Remove front mudguard (par. 104).

(3) Remove lock nut from steering damper rod, then remove upper end parts in the following order: adjusting nut, keyed steel washer, fiber washer, operating lever, and actuating sleeve. This entire assembly is located in the central part of the handle bar mounting bracket.

(4) Steering damper rod, cushion spring, pressure disk, fiber disk, and steel disk assembly can now be withdrawn (downward) from fork stem hole.

b. Install (fig. 65). Before installing steering damper, make sure that the parts are in correct order on the lower end of the rod before passing rod up through hole in fork stem. Check parts and order of assembly.

(1) Assemble parts on rod end (fig. 65), making sure that the bent down lip of the steel pressure disk engages with notch in end of the rod lock plate.

(2) Pass rod with its lower end assembly up through hole in fork stem, turning steel pressure disk to front position so that “bent‐up” lip engages with notch in front side of rigid fork crown, at the same time engaging curved end of steel disk torque arm in slot in underside of frame head. Maintain pressure against end of rod to keep lower disks in order while assembling upper rod end parts.

(3) Install upper rod end assembly in the following order: Small plain washer, releasing spring, adjusting sleeve screws into end of fork stem, operating lever registers on the adjusting sleeve, fiber washer, keyed steel washer registers in rod slot, large adjusting nut, and lock nut.

(4) Turn actuating sleeve all the way into fork stem and then back it out (up) ½ turn or more. Register the operating lever on flat of actuating sleeve, and see that lever has full movement to the left without bottoming sleeve in the fork stem.

(5) Adjust steering damper by setting adjusting (large) nut so that operating lever must be moved nearly straight back from the free (left‐side) position, before damper takes noticeable effect (applies friction to movement of the handle bars). Hold large adjusting nut and tighten the small lock nut.

(6) Install front mudguard (par. 104).

(7) Install front wheel (par. 125).

100. HANDLE BARS.

a. Remove Complete Assembly. If vehicle is equipped with handle bar windshield and rear view mirror, remove these accessories before starting to remove handle bar assembly.

(1) Disconnect throttle control wire at carburetor lever, and spark control wire at timer lever.

(2) Release spark control wire housing clip at front cylinder base bolt (near timer). Also release housing from frame clip on left side of vehicle. Release throttle control wire housing clip, located at tank, lower front connection bolt.

(3) Remove front brake hand lever fittings from handle bars. Also release brake control wire housing at handle bar clamp.

(4) Disconnect battery negative ground wire at frame connection and wires at headlight. Headlight must be removed for access to the two terminal screws (fig. 73).

(5) Disconnect horn wire leading to handle bars and red wire (terminal No. 17, fig. 73) leading to handle bars.

(6) Remove steering damper rod upper end fittings in the following order: Lock nut, adjusting nut, keyed steel washer, fiber washer, operating lever, and operating sleeve (screws into end of fork stem). Removal of these parts gives access to handle bar lock nut. Remove handle bar lock nut and cone lock plate.

(7) Loosen handle bar bracket‐fork end pinch bolts. Handle bars are now free to be drifted off ends of fork sides and center stem.

(8) Remove handle bar windshield apron spring guard after handle bars are removed from vehicle.

b. Install Complete Assembly. If vehicle is equipped with handle bar windshield and rear view mirror, attach these accessories after handle bar assembly is installed.

(1) Attach windshield apron spring guard to handle bar bracket. Do not tighten bolt nut until after handle bars are installed.

(2) Start handle bar bracket holes over ends of fork, seeing that spark control wire housing is on right side of frame head: then drive handle bars onto fork ends, using a rawhide mallet, or a hammer and wood block.

(3) To install cone lock plate, enter registering pin through hole in handle bars and engage notch in the adjusting cone. Install and tighten handle bar lock nut securely. CAUTION: When tightening this nut, always make sure that register (shoulder) of nut enters hole in lock plate and handle bars.

(4) Check adjustment of head bearing. The fork must turn freely but without perceptible shake. Readjust head cone to obtain proper bearing adjustment if necessary.

(5) Tighten handle bar bracket‐fork end pinch bolts.

(6) Position windshield apron guard so that it clears fork springs. Securely tighten mounting bolt nut.

(7) Install steering damper upper end fittings (fig. 65). Make sure that lower end disks and plates are properly engaged. Adjust (par. 99).

(8) Connect handle bar wires to terminal plate, horn, and headlight. Consult wiring diagram (fig. 73). Install headlight. Adjust beam and secure mounting nut (par. 114). Connect battery negative ground wire to frame connection.

(9) Check operation of lights and horn, tactical situation permitting.

(10) Attach front brake hand lever fittings to left handle bar. Secure control wire housing in handle bar clamp, just ahead of housing oiler. Check front brake for correct operation and, if necessary, adjust (par. 97).

(11) Pass spark control wire housing along left side of frame front tube, between cylinders (under carburetor) to position housing end clamp on cylinder stud near timer. Secure clamp under cylinder stud nut. Secure wire cable under clamp on left side of frame front tube, with white paint mark slightly ahead of clamp front edge. Engage end of spark control wire in timer lever and adjust spark control (par. 88).

(12) Pass throttle control wire housing along right side of frame front tube and over top of front cylinder head to reach carburetor connection. Install tank (lower front) mounting bolt to secure wire housing clamp. See that white paint mark on wire housing is slightly ahead of clamp, then secure bolt nut on left side of vehicle. Engage end of throttle control wire in throttle lever and adjust (par. 69).

101. HANDLE BAR CONTROLS (figs. 66 and 67).

a. Construction of the throttle and spark controls is the same, thus replacing a control wire or wire housing follows the same general procedure up to the point where control adjustment is made. Handle bar grip sleeves (spirals) are interchangeable.

b. Remove Throttle Control Wire (fig. 67).

(1) Disconnect control wire at throttle lever connection.

(2) Insert blade of a large, square‐shank screwdriver through hole in end of grip and turn out end nut by using a wrench on the shank of the screwdriver (fig. 66). Sometimes this nut is difficult to remove. In this case, insert punch into the slot in the nut and strike punch two or three sharp blows to “free” nut in handle bar end threads. Remove nut as above. NOTE: Nut remains inside the grip and is removed with the grip and spiral sleeve assembly.

(3) Remove grip and spiral assembly from handle bars. Control wire and working parts are now accessible.

(4) Remove plain roller from pin. Remove roller block from pin. Remove pin from plunger.

(5) Pull plunger with wire attached out of handle bar end. Remove hexagon head screw which secures wire to plunger. NOTE: If wire is broken, remove other half from housing at carburetor connection end.

(6) Remove any rust, dirt, or gum from grip spiral, handle bar end, wire plunger, and inside of handle bar where plunger operates.

c. Install Throttle Control Wire (fig. 67).

(1) Pass hollow screw over control wire with threaded end of hollow screw facing button on end of wire. Install screw in end of plunger. Securely tighten screw.

(2) Apply grease or engine oil to control wire and insert end into control wire housing.

(3) Apply grease to plunger and push plunger and wire into handle bar until plunger pin hole is exposed in handle bar slot. Work plunger or turn it within handle bar so that pin hole and flat side are upward and are centered in slot; then insert roller pin into plunger hole, roller block (with flat sides), and roller in order named. Apply grease to plunger pin and roller and to outside of handle bar end.

(4) Install grip and spiral assembly by engaging plunger roller in spiral opening in end of grip sleeve. Grip spiral sleeve nut can best be started without danger of cross threading, by holding grip assembly back slightly while starting nut in handle bar end. This squares nut with end of grip sleeve, alining threads. Securely tighten nut with screwdriver and wrench.

(5) Connect control wire at throttle lever connection. Adjust control (par. 69).

d. Remove Spark Control Wire (fig. 67). Disconnect control wire at timer lever and follow procedure outlined under step b above.

e. Install Spark Control Wire (fig. 67). Follow procedure outlined under step c above, then connect control wire at timer lever and adjust control (par. 88).

f. Remove and Install Control Wire Housings. Remove either control wire housing after following procedure outlined above (step b), then remove set screw on under side of handle bar, just ahead of grip sleeve shoulder. NOTE: Set screw for spark control wire housing is located under headlight dimmer switch. After set screw is removed and housing freed from attaching clamps, housing can be pushed out through end of handle bar.

(1) When installing control wire housings, see that housing end is secured in handle bar with set screw, and that housing is correctly attached to vehicle clamps.

(2) Install control wire and grip (step c above) and adjust controls: spark (par. 88), throttle (par. 69).