Front Fork Disassembly Norton Commando
This article shows how to disassemble front forks on 1972 and later Norton Commando models.
![Norton Commando front fork disassembly front fork disassembly Norton Commando](http://www.classic-motorcycle-build.com/image-files/xnorton-commando-remove-fork-tubes.jpg.pagespeed.ic.LsM1UYkVNM.jpg)
To read about how to remove forks from the bike click here.
To read how to assemble forks click here.
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After removing the fork tubes and draining out the old oil, the fork assembly was placed upright in a workbench vice between two soft jaw pads.
Fork Seal Dust Covers
![applying heat to rubber fork seal cover remove fork seal dust cover Norton Commando](http://www.classic-motorcycle-build.com/image-files/xremove-fork-seal-dust-cover-norton-commando.jpg.pagespeed.ic.UgbrmkbIj7.jpg)
The old hardened dust covers slide off easily with the help of a heat gun.
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Damper Assembly
Repositioning the lower fork horizontally, remove the 5/16 UNF x 5/8" bolt on the very bottom of the slider.
![front fork disassembly Norton Commando 1974 Norton Commando restoration](http://www.classic-motorcycle-build.com/image-files/xfront-fork-disassembly-norton-commando-72.jpg.pagespeed.ic.5Mj7rMjysn.jpg)
You'll need a deep-wall 1/2" socket to fit into the recess.
![new fork tubes Norton Commando replacement fork tubes Commando](http://www.classic-motorcycle-build.com/image-files/xfront-fork-disassembly-norton-commando-74.jpg.pagespeed.ic.bAf2PgecjP.jpg)
Did a flat metal washer come off with the bolt?
![fork slider bolt washer Norton Commando Norton Commando disassemble front forks](http://www.classic-motorcycle-build.com/image-files/xnorton-commando-disassemble-front-forks-73.jpg.pagespeed.ic.YSxDJrKvSp.jpg)
This washer often gets stuck and has to be fished out.
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Fork Seal Collar Removal
All too often, fork seal collars are chewed-up and over-tightened.
![Channellock pliers to remove fork seal collar 12 inch channellock pliers](http://www.classic-motorcycle-build.com/image-files/x12-inch-channellock-pliers-03.jpg.pagespeed.ic.jpBnthMCN1.jpg)
This is not the best way to remove them, but I used to a pair of Channellock pliers, which left 'tooth marks' in the collar. I was able to remove the marks with a file, and then a wire-wheel on a bench grinder.
![refurbish fork seal collar Commando fork collar removal](http://www.classic-motorcycle-build.com/image-files/xcommando-fork-collar-removal.jpg.pagespeed.ic.BsqOZ6ywUE.jpg)
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Remove Fork Stanchion Assembly
The next step in disassembly is removing the stanchion from the lower fork.
![front fork disassembly Norton Commando fork disassembly Norton Commando](http://www.classic-motorcycle-build.com/image-files/xfront-fork-disassembly-norton-commando-73.jpg.pagespeed.ic.9isCXRwJjF.jpg)
Using the stanchion as a slide hammer, a couple of swift pulls should separate it from the slider.
![remove fork stanchion from lower fork replacement fork tubes Commando](http://www.classic-motorcycle-build.com/image-files/xremove-fork-stanchion-from-slider-72.jpg.pagespeed.ic.5jDihEpzOl.jpg)
Along with the stanchion, the oil seal, paper washer, bronze bushing, and steel bushing will come out.
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Fibre Washer
Look inside the bottom of the lower fork leg. There should be a fibre washer.
![replace fork tubes Norton Commando replace fork tubes Commando](http://www.classic-motorcycle-build.com/image-files/xreplace-fork-tubes-norton-commando-74.jpg.pagespeed.ic.kpTWP1H49C.jpg)
This often gets stuck, and can easily be overlooked. I used a picker-outer tool and pushed it out from the bottom.
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Fork Damper Assembly
The fork spring is held in with a 5/16" UNF nut and thick washer on top of the fork damper rod.
![front fork overhaul Norton Commando Norton Commando fork overhaul](http://www.classic-motorcycle-build.com/image-files/norton-commando-front-fork-overhaul-01.jpg)
Removing the nut and washer removes the spring.
![fork damper rod assembly Norton Commando Norton Commando fork damper rod with spring](http://www.classic-motorcycle-build.com/image-files/damper-rod-assembly-norton-commando-72.jpg)
With a Phillips screwdriver in the vice holding the damper tube, the damper cap can be removed with a 1/2" wrench.
![damper rod valve and seat disassembly Norton Commando Norton Commando front fork overhaul](http://www.classic-motorcycle-build.com/image-files/norton-commando-front-fork-overhaul-04.jpg)
The bottom end of the damper rod has a roll pin, damper rod valve, valve seat, and 3/8" UNF nut.
![fork damper disassembly Norton Commando Norton Commando front fork disassembly](http://www.classic-motorcycle-build.com/image-files/fork-damper-disassembly-norton-commando.jpg)
On the bottom of each stanchion is a steel bushing held on by a C-clip, which are best removed with snap-ring pliers. Having three hands here is helpful.
![fork bushing circlip removal Norton Commando Norton Commando front fork disassembly](http://www.classic-motorcycle-build.com/image-files/fork-bushing-circlip-removal-norton-commando.jpg)
Parts Inspection
At this point, all parts should be cleaned and inspected for re-use. Brake parts cleaner works well, and leaves no residue.
Carefully check fork tubes for nicks or deep scratches, either will cause new seals to leak.
![check motorcycle fork tubes for straightness check fork tubes for straightness](http://www.classic-motorcycle-build.com/image-files/check-motorcycle-fork-tubes-for-straightness.jpg)
To help check fork tube straightness, I notched two 2x4's into V-blocks. Another way to check straightness is hold the two tubes up next to each other and slowly turn them.
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Related Work
One of the two fender retaining studs was snapped off in the left slider.
![remove broken bolt from aluminum fork slider remove broken stud from aluminum](http://www.classic-motorcycle-build.com/image-files/remove-broken-bolt-from-aluminum.jpg)
After center punching, the slider was fitted in the drill press vice.
![remove broken stud from aluminum fork slider Norton Commando build](http://www.classic-motorcycle-build.com/image-files/remove-broken-stud-from-aluminum.jpg)
After drilling a small pilot hole, two progressively bigger holes were drilled, until a spiral extractor could be fitted.
![remove broken bolt from aluminum fork slider remove broken stud from aluminum](http://www.classic-motorcycle-build.com/image-files/remove-broken-bolt-from-aluminum-02.jpg)
With the front forks completely disassembled, now is a good time to polish the lower legs.
![before and after polishing aluminum motorcycle forks motorcycle forks before and after polishing](http://www.classic-motorcycle-build.com/image-files/aluminum-fork-polishing-norton-commando.jpg)
If you're not sure of the history of the steering head bearings, it may be wise to replace them while the front end is off.
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Short vs Long Gaiters
The purpose of 'accordion' rubber fork gaiters is to protect the bare stanchions from dirt, dust, rocks, and other harmful debris.
![short vs long fork gaiters Norton Commando build](http://www.classic-motorcycle-build.com/image-files/xshort-vs-long-fork-gaiters.jpg.pagespeed.ic.mff-8gtUVj.jpg)
Most U.S. bound bikes received short stiff gaiters that offer no protection.
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![front fork assembly Norton Commando Norton Commando replace fork seals](http://www.classic-motorcycle-build.com/image-files/xfront-fork-assembly-norton-commando.jpg.pagespeed.ic.6Sp3pjVRGK.jpg)
Read: Front Forks Overhaul
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Parts Diagram
Andover Norton offers a large exploded view of Commando front forks on their website. To see it click here.
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Norton Commando Articles:
Norton Commando Build - Homepage
Cylinder Head Removal
Fork Tube Removal
How To Polish Motorcycle Forks
Norton Commando Upgrades
How To Polish Aluminum
DIY Motorcycle Tools
![measure bushing inside diameter with digital micrometer replacement fork tubes Commando](http://www.classic-motorcycle-build.com/image-files/measure-bushing-inside-diameter-with-digital-caliper-03.jpg)