Norton Front Forks
Atlas/Commando
Factory shop manual errors
The fork assembly's comprise of the fork stanchions, lower
legs or bodies, the dampers, and springs.
The factory shop manual pn 065146, I believe, is in error
in it's description on how the commando forks function. Figure G2 and text
section G2...especially in regards to the early commando (and atlas).
Atlas
Commando measurements
in inches
potential damper travel- 6.25/7.312
damper body length- 7.75/9.125
fork travel- 6.15/6.15
damper rods- 19.875/19.875
fork staunchions- 21.875/23.187
damper bottom bolt- 26cei/24unf
damper top cap- 26/28
TPI
damper rod top thread 3/8"- 26cei/24unf
Covenant Conversion
Bottom bump stop mod analysis
The Covenant conversion is an interesting bit of craftsmanship.
This is mainly due to the positioning of the bump stop holes on the early
models below the taper apex. This kit is legitimately needed
for these early versions. If the vent holes are below the taper apex,
then the oil flow into the center of the damper body is unimpeded. In this
condition the forks have NO bottom hydraulic bump stop. The conversion
kit plugs these holes to restore oil flow past the apex restriction
by relocating the holes above the taper apex like the later commando
forks which do have some hydraulic bump stop.
A few specifications to allow analysis.
(I assume I have typical components......)
The damper body taper apex is 1.010" in diameter.
The fork tube ID is 1.022" diameter
The vent holes (2) on the late commando are .250" diameter
Analysis
The 2 vent holes area summed is .098 in/sq.
Some high school math shows that at full restriction (fork and damper
meeting at taper apex) you have .0192358 in/sq.
This represents the minimum area that fluid can pass through and thereby
constituting hydraulic bump stop.
If the math is done to find out the diameter of the taper where the
aperture, between the taper and fork tube ID, is .098 in/sq,
it can be determined that that happens at .959" diameter. It seems like
poetic justice that it just happens to cooincide with the center of the
2 vent holes.
Therefore as the fork tube passes down the ever decreasing size vent
hole, and increasing size of taper on the damper body, the hydraulic bump
stop becomes ever harder as would be expected. If the vent holes are moved
even 1/8" higher, there would be NO further modification on hydraulic
bump stop operation possible. It simply has no further effect. Finally,
the fork bottoms out against the fork leg before coil bind happens. The
bump stop taper apex is .55"above final fork bottoming out
Covenant Conversion
Top hydraulic bump stop
The factory manual eludes on the drawing and in the text that as the fork
extends that the large hole becomes blocked off by the upper bush to start
the function of a hydraulic bump stop and finally the small hole
becomes blocked by the upper bush and final hydraulic stop is complete.
THIS
IS AN ERROR.
this is why
The fork damper rod tops out in the damper, 0.6"before the
fork is extended enough to start to block off the big hole in the fork
tube. This topping out action is also 1.25" short of reaching the smaller
bump stop hole. The damper topping out limits the fork to 1.55" less
travel than the bushes would otherwise allow. The reasons the factory manufactured
the forks this way may hopefully be made known to us all one day.
A longer damper rod 'would' allow for more fork extension, an therefore
more fork travel.
The need for this extra travel may continue to be controvertial. Topping
out is usually cured by renewing the damper cap and rusty damper rod
The pix shows
(left) a late model commando damper body with 2 vent hole above taper
apex.
(center) a early commando with 4 vent below taper apex,
(right) a shorter atlas damper body with 4 vent holes below the taper
apex.
Damper bodies