The following is a posting of a Ceriani 35mm Road Racing Forks manual. The year of issue of this manual is unknown. The contents of this reprint cover; Ceriani Models 1.716/R (29") and 1.207T/R (27") and include; Assembly Instructions, Assembly Drawing, Parts List and Parts Drawing.

INlTlAL ASSEMBLY INSTRUCTIONS
(Refer to Assembly Drawing)

Your new Ceriani fork is supplied to you in its original factory wrapping to ensure it reaches you in the best possible condition. After removing the wrappings completely, please follow the instructions below to install the single most important improvement to your machine’s handling - a Ceriani front fork!

  1. Remove all pinch bolts and allen bolts from upper triple clamp (crown) (24) and lower triple clamp (base) (23). Insert steering stem (22) (suitably machined to fit your motorcvcle’s bearings, if necessary) into center hole of base, ensuring that the clearance cut faces rearward, and reinstall pinch bolt.

  2. Remove top nut/rod assembly (D) from stanchion (7). This can be done by wrapping the stanchion tube in several layers of rag and clamping in a bench vise to allow use of 30mm wrench to unscrew nut. Alternatively, the top nut can be temporarily clamped in the vise and the stanchion unscrewed using hands only to grasp the tube. No tools or straps are to be used on the stanchion tube.

  3. Clamp steering stem (22) vertically in vise. If no vise is available the stem can be installed in the motorcycle (See Section 7) provided the machine is securely propped on shop stand or other suitable base under the frame. Insert each stanchion up through the proper hole in the base, replace (but do not tighten) the base pinch bolts. Position base lower than normal on the stanchion tubes (3 or 4 inches above boot/wiper tops). Place crown (top triple clamp) (24) in position on the stanchions (7) but not on the steering stem.

  4. In turn re-insert top nut/rod assembly into each stanchion making sure that the control rod (17) is properly inserted in the dampening adjuster (4). Note that the flat side on the rod corresponds to a slot in the adjuster. If the sliders are not fully extended, the rod will slip down through the adjuster when in proper position. This can be used as a check for rod position. Calibrate adjuster by rotating the 10mm control rod hexagon on (17) clockwise until the limit stop. Slightly loosen bottom screw (15) and continue to rotate the hexagon clockwise until its indicating line faces directly forward, i.e., in the direction the motorcycle will travel. Position lower legs so that drainscrews (28) face rear, use axle to line them up parallel. Tighten bottom screw (15).

  5. Fully tighten the 30mm top nuts (without moving the control hexagon). The 0 "Zero" mark on the top nut should line up with the indicating line on the control hex. If not, loosen the top nut slightly and turn the stanchion, but not the slider or hex control in order to have the hex line indicate "Zero" when top nut is fully tiqht (i.e., zero mark facing forward). After tightening down top nut ensure that the hex line indicates still "Zero" and that the adjustment is still at the clockwise limit stop.

  6. Temporarily tighten base pinch bolts. Remove top nut/rod assemblies. Remove handlebar clamps to increase working room. Insert springs and replace top nut/rod assemblies. Ensure that the rod (17) still engages adjuster (4) properly (it may be necessary to obtain assistance to compress spring slightly, enought to feel the rod’s flat side engage the adjuster) tighten top nuts to fix crown firmly in place. It may be helpful to extend the stanchions up throught the crown temporarily for even more working room.

  7. Remove from vise and, keeping base triple clamp in low position, install steering bearings onto stem (22) and into motorcycle’s steering head and position stem in the steering head. Install top bearing face and fit stem lock nut (25) to hold position. Adjust steering bearing play by tightening stem lock nut.

  8. Loosen base pinch bolts slightly, enough to let the stanchions slip slowly through. As crown settles onto top of steering stem, guide it to center tapping lightly with hide or plastic mallet to ensure a firm seating. Install stem cap nut (26) and pinch bolt.

  9. Assemble steering friction-damper, if required, as per exploded view on drawing and secure steady plate to suitable point on frame.

  10. The numbers 0-1-2-3-4-5 placed on the top nut indicate the various possibilities to regulating the dampening from "Zero" minimum to 5 maximum. Whenever it is necessary to replace some parts of the damping adjuster, it is recommended to perform the damping calibration again.

  11. Install wheel, fender, etc. Note that Ceriani forks are wider than most standard units and thus spacers may be required to center your wheel. Special race worthy Ceriani axles are available should your old axle prove unsuitable. Early Triumph wheels may require the use of this axle plus an adapting kit - (Part No. TRA-1). Complete instructions for mounting Triumph wheels are included with the kit. A special axle for B.S.A. Victor motorcycles is available on special order. The use of "Loctite" products is advised in the installation of any fork to be used in competition.

  12. Suggested procedure for initial installation and "Settling-In" of fork/wheel combination is as follows:
    1. Make sure that tops of stanchion tubes are even, using ruler or straightedge.
    2. Slip axle only into place. It should go in easily and then be able to rotate freely. If not, check step "A" and align as necessary.
    3. Tighten crown pinch bolts (29).
    4. Pump forks up and down several times.
    5. Tighten base pinch bolts (27).
    6. Install and tighten axle nut.
    7. Again pump fork several times.
    8. Tighten axle pinch-bolts.
    9. Attach brake strap (if required) brake cable, etc.

Ceriani forks are supplied complete with oil. This oil should be used only to break in the forks and should be changed after three hours use. The forks should be refilled with a suitable hydraulic (not motor) oil. The Ceriani factory has tested, approved and recommends “Lubri-Tech” racing fork oils for use in their forks. The following are the recommended amounts and grade of oil:

For 1.207/R (27") 175cc (6 oz.*) 5W each leg
For 1.716/R (29") 200cc (6¾ oz.) 5W each leg
For 1.595/R (Flattracker) 200cc (6¾ oz.) 5W each leg
*Amounts in ounces are approximate, measure in cc whenever possible

It is advisable that this change of oil be made before the forks are used in competition and after every third event thereafter.

If there are any signs of oil leakage on the wrappings of new fork legs or spillage during assembly, they should be drained and refilled to the above specification to ensure equal filling of both legs.

Oil seals and dust boots should be replaced at least once per season to maintain the high performance dampening characteristics of your Cerianis.

Care should be exercised to prevent the installation of accessories - fenders, fender braces, etc. from exerting pressure on the fork legs. Such pressure will interfere with the proper functioning ot the fork and will contribute to rapid wear.

SUB-COMPONENT RE-ASSEMBLY
(After service or repair, refer to Assembly Drawing)

COMPONENT (A): Damper & Adjuster Assembly
Assemble the damper (1), spring (2), ball (3) and adjuster and secure together with dowel (5).

COMPONENT (B): Stanchion & Adjuster Assembly
Insert component (A), valve (6) into the bottom of stanchion (7) and secure with circlip (8).

COMPONENT (C): Lower Leg (Slider) Assembly
Install oil seals (10), two per leg, in slider casting (9) and secure with circlip (11). Position boot/dust-wiper (12) on casting top and secure with clamp (13).

COMPONENT (D): Top Nut/Rod Assembly
Assemble the top nut (20), seal (19), inserting grommet (18), control rod (17) and secure all the parts with circlip (21).