Fork Removal

[TT Ashford]

Just put bike in garage and whilst locking it through front wheel noticed fork seal leaking. To tired to have a look at it now, but need to sort asap. How easy is it to get forks out? After taking wheel out, is it just unplug the adjusters, undo pinch bolts and pull out. Or does half the bike need disassembling as with most other tasks on the Trophy?

[Coconut]

Before committing to removal of the Forks and the subsequent work involved in replacing the Seals,
have a read of this Topic : Leaking front fork seal.


To remove the forks :

Normally the Trophy, when on the centre stand, rests on the front wheel,
so you need to find a way of dealing with that.

Some Members use a Jack and block underneath the exhaust downpipe but I don't
recommend this - Have you seen how much they cost if you damage them ? !

It is preferable ( IMHO ) to tie the rear end down, or place heavy weights / sacks etc.
on the pillion seat / luggage rack, or if you have the Engine Crash bars and are in a garage
you could use them - with ratchet straps tied up to hangers on the garage roof beams !

• Remove the ABS Sensor from the left fork leg - recover the shim between the sensor and fork leg.
  
• Remove the ABS Sensor wiring from the retaining clip.
  
• Remove both front brake calipers and support them so as not to strain the hoses.
  ( It's a good idea to place blocks of wood or similar between the brake pads
  to ensure the pistons don't find their way out of the caliper bores ! ).
  
• Remove the mudguard
  
• Remove the front wheel
  
• Remove the cover form the top of each fork, and disconnect each wiring plug.
  
• Slacken the upper yoke clamp bolt
  
• Slacken the two lower yoke clamp bolts
  
• Using a twisting action, withdraw the fork downwards from between the yokes.
  

I will also send you a Private Message shortly, with more information !

Cheers 

[TT Ashford]

👍👍 thanks for info Coconut, have sent pm.

[sin_tiger]

I have to do a fork removal as well, long story. I don't have a service manual, there is one question that I think I know the answer but if anyone knows for certain, verification would be good.

After disconnection of the TES plugs and subsequent reconnection, will the TES recalibrate itself without the need to be reset with the Triumph dealer interface?

[Coconut]

Owners Handbook Page 54 :

System Calibration.

The system will re-calibrate the damper adjustment
motors each time the ignition is turned on,
and the pre-load adjustment motor after every 50 ignition on cycles,
once the engine is started.

Damper adjustment motor calibration takes approximately 2 - 3 seconds,
and pre-load motor calibration takes around 20 - 30 seconds.

As far as I am aware the front forks only have Damper adjustment
( as above calibrated at every Ignition ON ),
whereas the Rear Suspension Unit has Damper adjustment and Pre Load adjustment.

I've also sent you a PM with more information. 

Cheers 

[sin_tiger]

That's what I'd think too, good to get a second opinion 

[1675]

Before stripping the fork leg for seal replacement, I would recommend you try a "Seal Mate". Available from a well known auction site for around £6 and the sceptic in me thought it wouldn't work, but did.
The leg still has to be taken out to refill it with oil, but this method avoids a whole load of dismantling and rebuilding which needs special tools. Hope this helps.

[Ade52]

I was lucky enough to have fork seals done when i bought the bike as both legs puked oil over the discs, after a 3hour ride home after purchasing the bike. Therfore, Hopefully I should be ok for a long time. But to save me thumbing through the w/shop manual can you inform me why the forks have to be removed to replenish/change oil as I have not had to do this with other bikes I have owned. It seeems a long winded process if you only want to change the oil after a service intival Thanks - Ride Safe Ade.