Headlight brackets stuck & loose for stem

All,
I have recently acquired a 1972 750 Roadster which I'm in the process of dismantling before restoring it.

I'm having trouble getting the fork stanchions slide through the headlight brackets. I have slackened the pinch bolts and loosened the top nuts and although the stanchions can turn in the yolks (together with the headlight brackets), I cannot get them to slide out. I have tried repeated beating with a club hammer and block of wood on the top nuts but they seem stuck to the brackets.

The brackets are stainless so I don't think they are rusted in place, maybe the 'O' rings are trapped between the stanchion and bracket?

I also noticed that the steering stem is loose in the top yolk, it turns when I try to loosen the bottom nut. Is there a fix for this or will I need a new set of yolks?

All info welcome.

The stem is pressed into the top yoke and normally not easily removable. No way the headlight ears are holding anything. If you have the bottom pinch bolts loose and the tubes rotate, there may me a slight ridge from overtightening the pinch bolts that could keep the tubes from coming out. Try removing the pinch bolts and wedging the clamps open a bit more before you whack on the crown nuts.

If the bottom yoke retaining nut spins and does not loosen, you may be able to punch the stem out of the top yoke and get it to drop down. This normally would be done with a hydraulic press, but if it's loose enough to spin, it should come out with a little persuasion.

gunnag said:

I'm having trouble getting the fork stanchions slide through the headlight brackets. I have slackened the pinch bolts and loosened the top nuts and although the stanchions can turn in the yolks (together with the headlight brackets), I cannot get them to slide out. I have tried repeated beating with a club hammer and block of wood on the top nuts but they seem stuck to the brackets.

The brackets are stainless so I don't think they are rusted in place, maybe the 'O' rings are trapped between the stanchion and bracket?

I also noticed that the steering stem is loose in the top yolk, it turns when I try to loosen the bottom nut.

Click to expand...

The stanchions are a taper fit in the upper yoke so if you are sure you have separated the tapers then yes, it might be the O-rings jamming especially if a previous owner has attempted to fit them inside the bracket tubes where they do not belong.

gunnag said:

Is there a fix for this or will I need a new set of yolks?

Click to expand...

I'm sure it could be repaired, either by (copper?) plating the stem or fitting a sleeve. Edit: or welded, apparently.

(They are 'yokes' not 'yolks' :wink: )

Danno said:

If the bottom yoke retaining nut spins and does not loosen, you may be able to punch the stem out of the top yoke and get it to drop down. This normally would be done with a hydraulic press, but if it's loose enough to spin, it should come out with a little persuasion.

Click to expand...

I think there is a circlip at the upper end which prevents the stem from being either pulled or drawn down through the yoke so I think the stem has to be pressed upwards to remove it.

Perhaps better to partially saw through the nut and then split it to release the upper yoke and stem.

Thanks for the replies, I have now managed to remove the stem nut using a socket and a 12v wheel nut impact wrench. After the nut was removed, the stem and top yolk came out fairly easily from the two bearings in an upward directions using a few light taps from a hammer (threads protected).

So I'm now in a situation with the stanchions still in the lower yolks and able to turn freely, however the headlamp brackets still wont budge and seem to be glued to the stanchions. I can only imagine that a previous owner has used silicone or something to secure the headlamp brackets in place. Guess my only option is to slice down the sides of the the brackets with an angle grinder and then open them up. Seems a shame as otherwise they are in good condition.

Try heating them up with a blow torch as evenly as possible to try and break down the bond. If they are stainless an change colour it should polish out again an as cutting them will ruin them anyway you have not much to lose.

This is the top end of a new stem, showing the circlip groove and the knurled section, hopefully the knurling only is worn and a new stem is all you need, this one is surplus to requirements and never fitted.

Thanks Kommando,

I just pulled out my steering stem, pic below, as you can see there is some wear, hopefully a new stem & some Loctite would fix it.

Kommando PM me if you have a stem available.

most any machine shop should be able to knurl it again.

gunnag said:

Thanks Kommando,

I just pulled out my steering stem, pic below, as you can see there is some wear, hopefully a new stem & some Loctite would fix it.

Kommando PM me if you have a stem available.

Click to expand...