Section G8 - Refitting Front Forks

This is basically the reversal of the dismantling procedure.

1-5) These steps are about reassembling the yokes, which I didn't do - so no comments

6) Pass the fork legs through the lower and upper yokes, pulling them into the tapers using the instrument cases, washers and large chrome bolts. 

7) With the fork legs secured, snug up the socket head pinch bolts.

8) Now tighten up the fork securing points in this sequence: Chrome bolts, fork stem nut, lower yoke pinch screws. 

9) The fork stem nut should be torqued to 15 lbs/ft and the tab washer bent over.

10) Remove the large chrome bolt so you can fill with oli and connect the damper rod to the bolt. The stock dampers require 150 cc of SAE 20 fork oil. The Landsdowne dampers require 150cc of SAE 10 oil. The oil can take a while to work it's way down, so you'll have to be patient. After the oil has been added, connect the damper rod to the chrome bolt and then tighten the chrome bolt to the yoke at 40 lbs/ft.

(Ooops - forgot to put the instrument case on first...)

11) If you removed the master, reattach to the switch cluster

12) Bolt the caliper assembly to the fork slider using the two bolts and washers to 25 lbs/ft.

13) Fit the front fender

14) Refit the front wheel

15) Clip the hydraulic hose back in the spring clips.