Norton Commando Workshop Manual

## Front Forks/Steering

# G

### SECTION G3

### REMOVAL OF FRONT FORKS

Removal of the front forks is most easily achieved by dismantling in parts rather than attempting to remove the fork assembly complete. Pre 1971 models had the steering stem captive in the lower yoke whereas 1971 and later models have the stem captive in the upper yoke. This alters the dismantling procedure for the yokes. In the case of disc braked models, it will be found easiest to remove the hydraulic system as an assembly, thus relieving the necessity for refilling and bleeding the system. Release the hydraulic pipe bracket from the right fork slider at the fender bridge. Remove the two bolts and spring washers securing the caliper to the slider and lift the caliper away, complete with pads and still attached to the brake hose. At this stage if the brake lever is operated accidentally, the pads and pistons will be forced from the caliper and the fluid lost. To protect against this, place a spacer between the brake pads - a suitable piece of clean wood or preferably a piece of plastic tubing would be ideal. Remove the four crossheaded screws securing the master cylinder to the right switch cluster, hold the master cylinder but allow the switch cluster to hang on its leads. Pull back the plastic switch cover from the master cylinder and disconnect both Lucar terminals. Release the large spring clips securing the hydraulic hose to the right fork leg and lift the complete hydraulic system away. The system is sealed and can therefore be laid down until it is to be refitted see Fig. G3. Support the motorcycle by using a box or block of wood beneath the lower frame rails and proceed as follows:
1 | Remove the front wheel (see Section H5 for disc brake wheel or Section H8 for drum braked wheel).
2 | Unscraw and lift the fork tube large chrome top bolts and using two spanners as shown in Fig. G7 release the damper rod from each top bolt.

3 | Lift clear the speedometer and tachometer in their cases and allow them to hang on the cables.
4 | Slacken the lower lug socket headed pinch screws (see Fig. G8).
The fork main tubes are a tapered fit into the upper yoke and require a shock to free them. The shock may be delivered by grasping the fork slider with both hands and snatching downwards several times. If this fails to break the taper, replace the chrome top bolt at least six threads without the instrument case and using a block of wood to protect the chrome finish (see Fig. G4) deliver several blows with a hammer. This will release the main tube from the upper yoke.

<< | < | rocbo.net | >