Maintenance Manual and Instruction Book, 16H, Big 4, 18 and ES2

Remove distance tube. From this side of the hub, drift out the remaining bearing, together with the peened in washer, felt washer and pen steel washer. 67. FRONT HUB, RE-ASSEMBLING. Pack bearings with grease. Press single row bearing into position followed by the distance piece (with collar 68. DISMANTLING OF THE BRAKES. Remove brake plate from the drum. Remove brake lever return spring from the lever. Remove nut and washer from the cam spindle. Remove brake lever. Remove cam and spindle from bush in the brake plate. Tap the end of the spindle lightly until the cam is clear of the shoes. Remove brake shoe return springs. Remove the circlips retaining shoes to the pivot pins. Remove the brake shoes. Cam spindle bush can be removed from the plate after removing the nut holding bush to the plate. 70. MAINTENANCE. Replenish damping oil at approximately 5,000 mile intervals. Remove hexagon headed filler plug from top of each fork leg. Remove drain plug from each fork end. Allow oil to drain out and operate the forks a time or two to eject the last drops. Replace drain plugs. Refill each leg with a measured | pint of Wakefield’s Castrolite, Single Shell or Price’s Motorine E. Work the forks a few times to remove any air-locks. Replace filler plugs. 71. STEERING HEAD ADJUSTMENT. Place a wooden block or box under the engine cradle of sufficient height to raise the 69. ASSEMBLY OF BRAKES. Fit cam spindle bush to plate.

against the bearing) felt washer and locking ring which can be tightened up. Insert distance tube through brake side of hub, ensuring that it is right home against the bearing just fitted. Press double row bearing into position. Fit pen steel washer and felt washer. Lightly rivet remaining washer into its recess.

BRAKES.

Fit brake shoes. Smear a little oil on th? pivot pins. Fit ONE shoe to pivot pin. Fit spring to the shoe fitted to the pin, near pin. Hold second shoe near to the one fitted and fit the spring, stretch the spring and fit second shoe to pivot pin. Fit second spring to both shoes. Fit cam spindle to plate. Hold shoes apart with screwdriver or similar tool and allow cam to pass the ends of the shoes. Fit NEW circlips to pivot pins. This is simplified if a length of rod is obtained with the same diameter as the pivot pin. Fit circlip to the rod. Place a piece of tubing over the rod. Place rod at the end of the pivot pin. Tap end of tube and circlip is forced on to the pin and into the groove. FORKS. front wheel clear of the ground. Place thumb of left hand on the joint between the steering head of the frame and the fork head clip. Attempt to lift the forks with the right hand. Any movement at the head races will be readily felt. To adjust, slacken the steering column locking nut and the pinch bolt clamping each leg into the fork crown. Adjust by means of the nut situated on the steering column below the head clip, until all play is removed, but the forks are still free to rotate on the head races. Re-tighten the steering column locking nut and the pinch bolts. 29

FRONT