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.
(7) Attach handle bar brake fittings and brake control wire housing to side of fork.
(8) Reinstall headlight, horn, and bracket assembly. Connect wires (per wiring diagram [fig. 73]) before front mudguard is reinstalled. Install blackout light (par. [114]). Reconnect battery negative ground wire to frame ground connection.
(9) Install steering damper (par. [99]).