Front fork tool

[Royal Rick]

Does anyone have a photo or exact description of the front fork tool referenced in the service manual for a 90cc? Or, what else might I use to reinstall my forks? Thanx.

[OldSwartout]

It is item 5 on page 56 of the 90-100 Parts Manual.  There is also a very poor picture of it in use in the BS 90 technical manual.

[CL-100]

During reassembly of one of the smaller bikes I use the swingarm bolt to help with assembly of the front forks.  Essentially it's a long 10mm bolt with the same 1.25 threads as the smaller bolts that go into the top of the forks.  I suppose it would be easier to use if it had a handle welded to it like the tool in the parts manual but I've never had a problem pulling the fork uppers up into the covers or through the triple tress.  Once in place, carefully remove the long bolt, and install the correct fork bolts.  Sometimes the upper fork may retract a little and get out of reach of the fork bolts, but if you're careful and don't move it too much, you'll be OK. 

Over time I've collected old m8, m10, and m12 long bolts to use for various purposes such as this. 

[Royal Rick]

Thanks guys, that jives with what Steve told me--just wanted to make sure I was doing it right.

[BRT-GTR]

          I've also heard of wooden dowel or a long, round handled artists brush handle being used to pull the fork legs up into position. Just screw the tapered end into the threads.

[ziggy stardust]

That's just how I did it Brian.



Z

[slawsonb]

You guys are so artistic!...yuk, yuk, yuk...
...bert

[BRT-GTR]

     Lee,
            That's probably where I remember it from. Can't beat a bit of 'artistic licence'  and lateral thinking when it comes to improvising a service tool !.

   Just used the BS clutch service tools for the first time. Found the tool to hold the centre tended to jump out of engagement with the teeth on the hub  . A short piece of 1/8th wire placed in the corner of the outer case, stops the pin on the tool from moving outwards and solves the problem.
   You need 2 pairs of hands to use the clutch basket stopper, it falls out of place for fun. A piece of 2x1 wedged from my bench to the clutch basket held the tool in place and allowed the ring nut to be removed or tightened single handedly. (Wife was busy :: and it takes longer to explain what you want them to do, than cut a piece of wood )

[OldSwartout]

I modified the clutch basket holding tool many years ago to keep it engaged in the holes.  I drilled a hole in each leg so that a short 6mm screw could be inserted through the legs into two of the puller holes in the bottom of the basket.

[BRT-GTR]

        Now why didn't I think of that ! (No answer required  ).   Great idea Karl, I'll modify mine the same way.
                 Brian

[OldSwartout]

The screws to hold the tool to the basket need to be short, 10mm or so, or they'll dig into the housing behind the basket.