214 -Information On Model 149-249 Forks

INFORMATION ON ODEL 149-249 FORKS

How to Remove Fork Leg

1. Block motorcycle under front of frame until front wheel clears the floor.
2. Loosen lock nut and remove cable from front brake cam lever.
3. Remove threaded cable stop screw from lug at lower end of right fork leg and pass cable back through slot in lug until clear of fork.
4. Remove brake anchor nut and washer.
5. Remove axle nut from left side of front wheel and remove axle bolt from right side.
6. Remove front wheel from fork legs.
   Note: On some machines a spacing washer is used between the hollow axle and the left fork leg.
7. Remove the three mud guard brace bolts that are attached to the fork side being removed.
8. Remove the pinch bolt clamping the fork leg in the fork stem lower bracket.
   Note: It is mounted at the rear of the fork bracket next to the fork cover tubes.
   Note: It may be necessary to wedge open the split end of the bracket in stubborn cases of fork leg removal.
9. Remove cap nut from top end of fork leg.
10. Use hammer and brass drift to drive fork leg down from its taper seat in upper stem bracket.
11. Pull fork leg down till clear of lower bracket.

How to Assemble Fork Leg

1. Push fork leg up through lower stem bracket into tapered seat in upper bracket.
   Note: It may be necessary to bump lower end of fork upward and also necessary to wedge oopen the split portion of the lower bracket slightly.
2. Assemble the anchor screw into the upper threaded end of the fork leg through the upper bracket. Tighten.
3. Remove wedge, if any, and install and tighten the clamp screw in the lower bracket to firmly support the fork leg.
4. Install front wheel, entering brake anchor stud into the anchor boss on lower end of right fork and push axle through forks and wheel from the right side to the left.
   Note: A spacing washer may be needed between the hollow axle and left fork leg if any clearance is apparent. If the axle bolt draws the fork legs inward, they may bind.
5. Tighten front axle.
6. Install and tighten brake anchor stud nut and washers.
7. Fasten the mudguard brace bolts to the fork leg.
8. Slide brake cable into slotted anchor boss and return cable stop screw to its former position.
9. Enter brake cable adjusting screw into brake cam lever, adjust then tighten lock screw.
10. Remove motorcycle from blocking.
11. Bounce fork to test for freedom.
12. If tight, loosen front axle nut and test.
13. If improved, front axle needs a spacer washer.
14. Tighten front axle.

How to Refill Fork Legs with Fluid

1. Remove fork member and upper bracket anchor cap. This is the hex headed cap at the extreme top end of the fork sides.
2. Screw an 8″ rod with 8-32 threads into the upper end of the plunger rod (a wheel spoke can be used).
3. Remove special nut from the end of the plunger rod. the plunger rod will drop inside the fork about 4″, but you will be able to pull it back up by means of the threaded rod you have screwed in the end of it.
4. Remove front axle.
5. Remove fork plunger nut from inside of forging at the end of fork leg.
6. The Fluid may be drained out by pushing up on the lower end of the plunger rod.
7. After the fluid has been drained out, replace the nut and tighten it.
8. Replace front axle.
9. Pour slowly 8 ounces (1/2 pt.) of Love-Joy type of shock absorber fluid in through the top end of the fork.
10. Pull plunger rod up into position by means of the 8/32 threaded rod, assemble and tighten special nut and replace anchor cap.