(1) Assemble parts on rod end ([fig. 65]), making sure that the bent down lip of the steel pressure disk engages with notch in end of the rod lock plate.
(2) Pass rod with its lower end assembly up through hole in fork stem, turning steel pressure disk to front position so that “bent‐up” lip engages with notch in front side of rigid fork crown, at the same time engaging curved end of steel disk torque arm in slot in underside of frame head. Maintain pressure against end of rod to keep lower disks in order while assembling upper rod end parts.
(3) Install upper rod end assembly in the following order: Small plain washer, releasing spring, adjusting sleeve screws into end of fork stem, operating lever registers on the adjusting sleeve, fiber washer, keyed steel washer registers in rod slot, large adjusting nut, and lock nut.
(4) Turn actuating sleeve all the way into fork stem and then back it out (up) ½ turn or more. Register the operating lever on flat of actuating sleeve, and see that lever has full movement to the left without bottoming sleeve in the fork stem.
(5) Adjust steering damper by setting adjusting (large) nut so that operating lever must be moved nearly straight back from the free (left‐side) position, before damper takes noticeable effect (applies friction to movement of the handle bars). Hold large adjusting nut and tighten the small lock nut.
(6) Install front mudguard (par. [104]).
(7) Install front wheel (par. [125]).
100. HANDLE BARS.
a. Remove Complete Assembly. If vehicle is equipped with handle bar windshield and rear view mirror, remove these accessories before starting to remove handle bar assembly.