Lift the front end of the vehicle

To remove the handlebar upper: remove the two screws under the handlebar body and remove upper. (Fig. 39).

To detach Front Brake Cable from fork : release the cable adjuster group fitted to the shoe control lever, release the cable from the adjuster, withdraw cable from the guides on the back plate and from the front fork arm.

To detach the clutch cable from the control lever on the crankcase : rotate the lever (19 mm spanner) and remove the cable trunnion.

To remove the steering damper : loosen the damper locking wheel, remove upper quadrant and the friction quadrant, unscrew the two screws, their washers from the clamp, remove the half collar and support, remove the screws fixing damper to the steering (14 mm spanner) detach the quadrant from the handlebar clamp (see note in operation 104) (Fig. 40).

To remove handle without detaching the other cables; slide handlebar body from fork by tapping it with mallet, and turn it over without causing sharp bends to the cables.

To remove the fork : unscrew the lock ring fixing screw (Fig. 41), unscrew the ring (Fig. 42) (Tool No. . 65390) unscrew the ball race adjuster ring (Tool 40482), remove the ball race and slide fork down­wards (Fig. 43).

Grease lower ball race cone on fork, fit ballrace into the cone with its collar downwards. The correct assembly and adjustment of the steering is checked by rotating the fork, which should be free to move without rubbing or play.

With the fork in a straight position, the right turn and left turn should require only a very little, and equal, pressure. The adjuster ring on the upper steering ball race must be locked in position by the locking by means of two tools, Nos. 65390-40482, so as to avoid any possible rotation of the adjuster ring. Tighten the screw locking the ring.

NOTE: Where the steering ball races and cones have been removed, it is important that their assembly be carried out with tool ... to avoid possible distortions and faulty steering (Fig. 44).

To remove front brake cable: lift the front part of the vehicle, release the cable adjuster group, pull cable out of its guide on the back plate.

To remove the front wheel remove the two wheel spindle nuts on the trailing links (20mm spanner) and remove wheel. (Fig. 45)

Remove each rubber buffer for the fork's kick:

For Threewheelers up to frame No. 469618 unscrew inner hexagonal tap (14 mm spanner) of each buffer, and remove gasket (fig. 46).
For Threewheelers from frame No. 469619 dismantle swivelling gudgeon of jack (19 mm spanner), unscrew grease gun placed under the lever and two locking nuts of the lower buffer (10 mm spanner); then remove buffer with the help of a screwdriver.

Remove each wheel-carrier lever:

For Threewheelers up to frame No. 469618 unscrew nut and screw locking each iack (14 mm spanner), remove screw and withdraw lever with the help of a screwdriver from the splined pin (fig. 47)

For Threewheelers from frame No. 469619 use tool No. 58021 and press spring to draw out lever (fig. 47 his)

Remove each inner spring of the fork.

For Threewheelers up to frame No. 469618 remove 4 screws of each cover (8 mm spanner) (Fig. 48 ) ; remove the cover, withdraw the reaction lever, draw out the spring guide piston, suspension spring and auxiliary spring (Fig. 49). With suitable hook, draw out if necessary the spring rest washer.

For Threewheelers from frame No. 469619 draw out the slide bar, spring and, if need be, with adequate hook, the guide ring of the slide bar (Fig. 49 bis).

To remove the wheel spindle : remove the right hand side nut on the back plate (22 mm spanner) withdraw the back plate, the R.H. spacer, and the spindle by tapping towards the left and side. Extract spacer from left hand side.

Extract the two oil seals placed in the hub. (Fig, 50)

To remove front wheel bearings : remove the left hand circlip and with an extractor pull out the two bearings from the wheel hub, with their spacer.

To remove the steering damper follow operation 92.

Note : if the vehicle is used without the steering damper, it is vital that the screw fixing the handlebar to the fork is inserted and tightened, otherwise the handlebar will not be connected to the fork.

To dismantle the control cables; remove the two screws under the handlebar body, remove the handlebar upper. Release the trunnions of the clutch and front brka ecables from their levers on the crankcase and front wheel back plate repectively, detatch the cables. Remove the handlebar brake and clutch levers from their supports and detatch the cable nipples from them. (Pay attention to the small push pin and springs in the handlebar levers), unscrew the screws fixing the gear change and throttle cable pulleys, and slide off the clutch and brake lever supports. (Be careful with the pulley shims which must be replaced in the same position at assembly). Remove the gear and throttle cable nipples from the levers and draw cables out. (Fig. 51)

To remove electrical leads: unscrew the knurled button fixing the instrument panel to the dashboard, turn panel over and pull out the black/white - orange - red - black and blue/black leads from the junction box, under the panel.

Remove the horn grill, the horn, by unscrewing the nut fixing it, (14mm spanner) and pull out the white wires.

Unscrew the screws fixing headlamp rim, remove rim and reflector, and detach the blue - red wires from the lamphoeder.

To remove the handlebar remove the nut fixing the handlebar body (14mm spanner) remove the screw and the handlebar. Detach the steering damper qua­drant from the handlebar clamp. (See operation 103).

To substitute the control cables, withdraw the cables from the handlebar and after having released the other end of the cables.

(for the throttle cable it is necessary to detach the nipple from the carburettor end, and change the complete cables as both end nipples are soldered). Proceed with the substitution of the inner cables by inserting new ones from the handlebar ends. Grease inners before inserting into outers.