_Legend for Figure 63—Spring Fork Disassembled_]
(5) Remove front mudguard, after removing nuts and locks from rear rocker plate studs, two screws and nuts securing mudguard to rigid fork, and the two bolts mounting headlight bracket to mudguard. NOTE: _Front mudguard blackout light wire connects to ignition and light switch and care must be exercised not to break this wire if it is not disconnected from the switch._
(6) Disconnect battery negative ground wire at frame connection. Remove blackout light (par. 114). Remove headlight, horn, and bracket assembly as one unit.
(7) Remove handle bar brake fittings and brake control wire housing from side of fork. Remove handle bars after removing handle bar bracket lock nut and cone lock plate. It is not necessary to disconnect spark and throttle control wire housings from frame. Unscrew fork upper adjusting cone from fork stem, freeing fork assembly to be removed from frame head. NOTE: _Steering head ball bearings are loose (not in retainers) in upper and lower frame head bearing cups. Take care not to lose balls._
=h. Install Fork Assembly.= With vehicle on rear stand, and front end up by blocking under frame loop or skid plate, proceed with installing fork assembly, as follows:
(1) Thoroughly clean upper and lower frame head bearing cups and pack with general purpose grease No. 2, installing fifteen 5/16-inch ball bearings in each cup. Work grease thoroughly in between balls.
(2) See that lower fork stem cone is clean and in place, pass fork stem up through frame head, turning on upper adjusting cone. Do not try to adjust bearing cone as yet.
(3) Install handle bars by locating mounting bracket on ends of fork sides and center stem, making sure that spark and throttle control wire housings are in place.
(4) Adjust upper fork stem adjusting cone so that there is no perceptible shake in head bearings when handle bars are worked up and down, and fork does not bind when turned to right and left extremes.
(5) Install cone lock plate by engaging pin in one of the cone notches.
(6) Install lock nut on stem and tighten securely. NOTE: _Check head bearing play, as tightening lock nut sometimes makes head bearing too tight. Readjust if necessary._