Front end reassembly

Information relating to the Matchless G3 or AJS Model 16 350cc Heavyweight
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Front end reassembly

Postby DavidHW » Sat Oct 28, 2017 12:27 pm

Having now rebuilt the forks on my model 16, with rechromed stanchions, I'm now stuck on the reassembly. This is my first british bike after 50 or so rice burners and I love riding it, but think I've lots to learn on how they bolt together. Where I'm stuck is the folks go through the bottom yolks ok, but no matter what I do, stop about 4 inches from the top. I even tried putting on the front wheel and trying to bounce them up the yolks with no success. I'd really appreciate any tips (I think I must be missing something very obvious). Many thanks for any help you can give.

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Re: Front end reassembly

Postby dave16mct » Sat Oct 28, 2017 1:05 pm

You need to buy, make or borrow a puller. The club may sell them but they are easy to make from an old top fork nut ground or turned down, welded or threaded to a length of studding. Screw into the stanchion, then with a washer and nut pull it into the top yoke.
Dave

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Re: Front end reassembly

Postby 1608 » Sat Oct 28, 2017 2:45 pm

If you haven't access to a second hand nut and welding gear etc. then place a spindle or similar through or under both fork bottoms together. then place a ratchet strap ( everyones got one of those?) under the spindle and over the yokes. Use this to compress the springs and pull the sliders up far enough to let you lift the stanchion up and in to place by threading a pointed piece of dowel ( Like a sharpened broom handle) into the top of the stanchion.

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Re: Front end reassembly

Postby zwarts » Sat Oct 28, 2017 6:07 pm

Make or buy a proper fork puller. Don't mess about with broom handles or ratchet straps, it's such an easy job with the correct tool!

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Re: Front end reassembly

Postby SPRIDDLER » Sat Oct 28, 2017 6:39 pm

zwarts wrote:Make or buy a proper fork puller. Don't mess about with broom handles or ratchet straps, it's such an easy job with the correct tool!


:roll: Where's the fun in that? :roll:


(There'll probably be a broom or two passing over your shed sometime this evening ;) ).
What if the Hokey-Cokey is what it's all about?

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Re: Front end reassembly

Postby DavidHW » Sat Oct 28, 2017 7:45 pm

Thanks all, I've ordered a puller to add to my increasing collection of specialist tools. I love the engineering on these old British bikes, but it is becoming clear why the Japanese bike industry did so well in the 70s and 80s - they made a few small tweaks to make them easy and cheap to assembly on the production lines. Owning a British bike though has been a lot more fun than reading about them in books and filled in some of the history too.

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Re: Front end reassembly

Postby raffles » Mon Oct 30, 2017 7:25 pm

With a Cambridge location you should get to know the Fenrunners section of the Club you would have been able to loan the tool
and get instruction on how to do the job
Tony

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Re: Front end reassembly

Postby DavidHW » Mon Oct 30, 2017 7:35 pm

On my list of things to do Tony and a great idea. I was going to turn up at a meet on my bike, but then it developed problems that have kept it off the road for a few months (and I didn't want to turn up on an old Honda).

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