STEERING CONTROL
Paragraph
Forks 98
Steering damper 99
Handle bars 100
Handle bar controls 101
=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).
[Illustration: RA PD 315728
_Figure 63—Spring Fork Disassembled_
=A=—UPPER (RECOIL) SPRINGS
=B=—UPPER BUMPER SPRINGS
=C=—SPRING ROD LOCK NUTS (ACORN‐TYPE)
=D=—SPRING ROD BUSHINGS
=E=—LARGE SPRING ROD NUTS
=F=—LOWER CUSHION SPRINGS
=G=—SPRING RODS
=H=—LOWER BUFFER SPRINGS
=J=—SPRING FORK ASSEMBLY
=K=—ROCKER PLATE STUD NUTS AND LOCKS
=L=—RIGHT SIDE ROCKER PLATE STUD AND WASHER
=M=—LEFT SIDE ROCKER PLATE STUD (HAS BUTTON END) AND WASHER
=N=—AMMUNITION BOX CARRIER MOUNTING BOLT, WASHERS AND NUT
=O=—HEADLIGHT BRACKET AND MUDGUARD BOLT, WASHER AND NUT (LEFT SIDE)
=P=—FRONT AXLE, CASTLE NUT AND COTTER PIN
=Q=—SCABBARD CARRIER MOUNTING BOLT, WASHERS AND NUT
=R=—HEADLIGHT BRACKET AND MUDGUARD BOLT, MARKER LIGHT GABLE CLIP,
WASHER AND NUT (RIGHT SIDE)
=S=—BRAKE SHACKLE BOLT, LOCK AND NUT
=T=—BRAKE AND SIDE COVER ASSEMBLY
=U=—MUDGUARD BRACKET MOUNTING LOCK, WASHER AND NUTS (RIGHT SIDE)
=V=—MUDGUARD AND RIGID FORK MOUNTING SCREWS, WASHERS AND NUTS
=W=—MUDGUARD BRACKET MOUNTING LOCK, WASHER AND NUTS (LEFT SIDE)
=X=—NOTCHES IN MUDGUARD BRACKETS FOR SPECIAL LOCKS
RA PD 3157288
_Legend for Figure 63—Spring Fork Disassembled_]
(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).
[Illustration: RA PD 310266
_Figure 64—Compressing Cushion Springs for Spring
Fork Assembly_]
(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).
[Illustration: RA PD 310276
_Figure 65—Steering Damper Assembly_]
=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) 1/2 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).
[Illustration: RA PD 310282
_Figure 66—Removing Handle Bar Grip Sleeve Retaining Nut_]
=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.
[Illustration:
=A=—END NUT.
=B=—GRIP.
=C=—GRIP SLEEVE ASSEMBLY.
=D=—ROLLER PIN.
=E=—ROLLER.
=F=—ROLLER BLOCK.
=G=—PLUNGER.
=H=—CONTROL WIRE.
=I=—WIRE RETAINING NUT.
RA PD 310263
_Figure 67—Handle Bar Grip and Wire Control, Disassembled_]
=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).