FRONT SUSPENSION AND STEERING 105

 
8. Install the felt washer and dust cover over the shaft and install the steering shaft collar nut and turn it down by hand.

9. Tighten the collar nut 1/8 turn with a mallet and punch (see Figure 20).

10. Tap the bottom triple clamp upward with a soft mallet.  Then tap down on the top of the steering shaft.  Turn the bottom triple clamp back and forth to check for movement. 

11. If it feels too tight, loosen the collar nut.  If it feels too lose, tighten the collar nut another 1/8 turn.  Tap the bottom triple clamp and top of the steering shaft again and check the movement.  Repeat until the steering feels right.  It may be necessary to adjust the steering again after the front has been assembled.

12. Install the upper triple clamp and 27 mm nut.  Don't tighten the nut yet.

13. Clean the threads on the fender mounting bolts.  Install the fender on the lower triple
 

 clamp and the bolts, nuts and washers.  A thick flat washer fits under the head of each bolt and a flat washer and lock washer under each nut.  A flat fender mount plate fits under the four nuts.  Put Loc-Tite on the nut threads and torque to 6 ft.-lb.

14. On Pioneer models, install the horn and ignition switch bracket under the two forward fender mounting bolts (see Figure 21).

Fork Assembly

1. Install the damper piston on the damper shaft with the recessed end of the piston toward the bottom of the shaft (see Figure 22).

2. Install a new snap ring in the shaft groove with the square edge facing outward.

3. Hold the shaft upside down and install the rebound spring against the damper piston.

4. Install the damper valve disc with the spring washer facing away from the rebound spring (see Figure 23).
 

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