Service manual

09-4
✰ Measure the spring length.
✰ Inspect the other internal parts for
any visual damage.
FRONT FORK ASSEMBLY
✰ Assemble the front fork in the
reverse order of dis-assembly.
✰ Replace the oil seals and the ‘O’rings
with new.
STEERING DISASSEMBLY
✰ Remove the front fork assembly.
✰ Disconnect all wires and remove
headlamp unit and trafficators.
✰ Take out cover tube, bush and
washer.
✰ Remove head lamp assembly.
✰ Loosen the head lamp casing allen
screw.
INSPECTION
✰ Visually inspect all parts for
damages, cracks, bends, wear marks
or any other damage.
✰ Check the main tube for any bend.
P Remove the handle bar clamp bolts
and nuts and take out handle bar.
P Remove the stem lock nut and
washer carefully.
P Tap the steering stem downwards,
taking care to collect the steering
race balls (38 nos) for inspection.
✰ Remove head lamp casing.
✰ Drive out ball races and cover from
head lamp casing.
✰ Using a copper drift, tap out ball
race and cover from the frame head
tube.
Suspension & Steering