Question about 1996 Triumph Trophy 1200

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Front fork seals are shot and I need to replace them. I can't get the bottom bolt loose. It just spins in the fork leg with pressure.

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  • Triumph Master
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Use an air rattle gun with a hex driver

Posted on Apr 27, 2010

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1 Answer

How do I refill my fork tubes with fork oil


Begin by loosening the upper triple-clamp pinch bolts and breaking the fork caps loose while the fork is still held by the lower triple clamp. You will need to remove the caps to refill the fork tubes with oil.
Determine if the fork legs have oil drain plugs near the bottom of the legs. If they do, you are in luck and will be able to change the oil without removing the fork legs. Put old newspapers on the floor under the front end. Place a drain pan under the fork legs and remove the drain plugs, one side at a time. Hold the front brake and push down on the fork several times to pump the oil out. When oil stops coming out, reinstall the plugs using new sealing washers.
Without Drain Plugs
If there are no drain plugs (look carefully), you'll need to remove the fork legs to drain the oil. At this point you can decide to have it done professionally or do the work yourself. We'll cover the main, basic steps. Refer to a shop manual to learn all the exact procedures involved. Some motorcycles may require fairings, handlebars, etc. to be removed.
Support the motorcycle either on the centerstand (if equipped) or by using a motorcycle jack under the engine. If you use the centerstand, you may need to place a sandbag on the rear of the seat, hold the front end up using straps from the rafters, or support the bike underneath the engine. Use tie-downs to steady the bike on the jack. Grasp the lower fork legs and try to push and pull the fork toward the back of the bike and forward to check for loose steering head bearings. Inspect the pleated rubber fork boots, if equipped. Check for signs of fork oil leakage and any grooves in the fork tube wear surfaces where the seals make contact. Also check for looseness between the fork legs and tubes that would indicate bushing wear.
Remove the front wheel and axle assembly. Support and tie the brake caliper(s) out of the way. Remove the front fender and speedometer cable, if equipped. With the fork leg fully extended, remove the top cap from a leg. Be prepared as there may be some spring pressure pushing against the cap.
Loosen and remove the pinch bolt from the lower triple clamp and lower the fork leg. Note any shims or washers and spring. Turn the leg upside down in a drain pan until oil stops flowing out. You may have to move the damping rod in and out to get the oil out. Repeat the procedure for the other side.
Reinstall the fork legs and other removed components in the reverse order of removal.
All Models
Add the exact amount and type of oil recommended by the manufacturer. Some motorcycles call for the use of a dipstick to determine how much oil to use instead of just pouring a certain amount of oil back in. Follow the manufacturer's shop manual recommendations.
Carefully install the threaded top caps by hand to avoid cross-threading. Tighten the pinch bolts and top caps to the factory-specified torques. After the brakes are installed, pump up the lever until the brakes feel normal again. Once the bike is assembled and on the floor, push down on the front end to verify the suspension's response. Turn the steering from its left to right limits to ensure nothing is binding, and check all controls including the throttle for proper operation.

Mar 05, 2016 | Motorcycles

1 Answer

Change front fork oil seals


you need to remove the front wheel then on the bottom of each fork there will be an allen bolt recessed in. slacken this then undo the large bolts at top of forks. remove the brake caliper from fork leg and tie it up, dont just suspend it by the brake line. undo the pinch bolts on the yokes and withdraw each fork leg. continue to remove the allen bolt you slackened, drain the oil out of the legs and then pull the stanchion out of the fork bottom. the seals can now be prised out from the fork bottoms and new seals pushed in. assembly is a reverse of removal

Oct 25, 2013 | 2011 Hero Honda Splendor Plus

1 Answer

How to Replace front fork seals on Suzuki GSXR 1100 K model


Remove front wheel, brake calliper etc . Undo top and bottom yoke pinch bolts and slide out fork leg. Clamp chrome tube in a soft jawed vice and remove top nut carefully as it is under some load and will fly away, (but its not too much you can hold it with your hand). Tip out remaining oil slowly so as to not loose spacer on top of main fork spring. Clamp lower aluminium leg in vice by calliper mounts and remove allen screw in extreme end (if the wheel spindle was in you couldnt see it) This is the only part that might be a problem as the inner end may turn. An impact wrench may help or if not a simple broom handle shoved up the other end is often enough. Once this bolt is removed the leg will split. Now lever out the dust cover to reveal the wire circlip holding in the fork seal. Remove the clip and lever out carefully the old fork seal. Fit new seal using a large socket and mallet or something similar and reassemble in reverse order, not forgetting to add correct amount of new fork oil.

Jun 30, 2012 | 1989 Suzuki GSX 400 XS Impulse

1 Answer

Change fork seals


you need to undo the pinch bolts on the yolks and remove the front wheel & mudguard. Undo the bolys retaining the brake caliper and swing it towards the frame downtube, secure it with string. Withdraw each fork leg and clean up with a soft rag. On each leg, remove the top bolt (slowly to release spring pressure) and pour out the fork oil and discard it. Pour in a small amount of parrafin and swill it around a bit to clean out any residue. Remove the dustcap or gaiter and put it on one side. You will now see the fork oil seal. If it has a circlip then remove it, if not, then don't bother. Prise out old seal carefully making sure not to mark the soft alloy of the lower leg or the chrome on the stantion. Rub a little fork oil onto the new seal and carefully slide it over the stantion, pushing it all the way down. Use a piece of wood to firmly push the seal into the lower leg until it sits squarely and fully into place. Replace circlip if necessary and refit dust cover. Refill each fork leg with 142 ml of 10 wieght fork oil and replace top bolt. pump the leg a few times to settle the oil and then refit the legs in the reverse order of removal. When done, pump the forks a few times, go for a cuppa whilst it settles and then you are all ready to go.

Jul 02, 2011 | 1981 Yamaha XS 400 Special

1 Answer

How to change CB250rsz front fork oil and oil seals?


hi its been quite a while since i have done 1 of these but if the bike has the original forks on it i am sure you can do this without removing the complete fork of the bike, after suporting your bike you can chose to completely remove the fork if you wish, i would first try it without removing the complete fork first, remove front wheel, remove front mudguard and inner stabilizer, keep all bolts together in a safe place, you will need a clean container, to catch the fork oil,(TIP) if you catch all the oil and alow time for it to drip dry you can measure the amount of oil that was in the fork by pouring it from the container into a measuring jug, this will save time if you dont know the specific amount of oil required, to drain the oil you will need a suitable alun key to undo the fork leg/tube securing bolt, you will find this in the lower of the fork leg where the wheel spindle fits, turn the key anti clockwise to undo it, hopefully it will crack loose, if it just spins and doesnt undo you may need air tools to shake it loose, once the bolt is undone secure the fork leg and remove the bolt, the oil will then desperse from the fork, moving the fork lower slowley up and down will help rifle the oil out, make sure the sealing washer is on the bolt or you may have to fish around inside the old oil for it, when you are happy all of the oil has been removed, carefuly pull the fork leg down all the way until it comes of the stanchion, pour any oil into your container, if when you pull on the leg it does not come off this will be because the fork stanchion on your bike has bushes that are fited to it, and not to the lower leg, in this case you will have to remove the whole fork, remove, the dust cover from the fork leg inside you will see a circlip remove this and washer, remove cap from fork top and pour out your oil, and fork spring noteing direction , remove the lower bolt, fix the fork lower in a vice at the very bottom of the leg wher the flat area is, do not grip tubular area,then to remove the seal you will need to push down on the fork stancion to its lowest point, and sharply pull up useing the stancion as a hammer, repeat this untill your fork seal is removed, replace in reverse order, good luck hope this helps. paul

Dec 12, 2010 | Honda CB 250 Nighthawk Motorcycles

1 Answer

I need to change the fork seals on my 900 fireblade. do i need to split the forks.


HI WEATHER YOU NEED TO SPLIT THE FORKS OR NOT, YOU SHOULD, SOME OF THE OLDER HONDAS REMOVING THE LOWER FORK BOLT, ACCESABLE WHEN THE SPIINDLE HAS BEEN REMOVED, THIS WILL DRAIN THE OIL OUT OF THE FORK LEG THERE WILL BE A WASHER OR SEALING RING ON THIS SO BE CAREFUL NOT TO LOOSE IT WHEN YOU REMOVE THE BOLT, USING A BOWL OR CONTAINER TO CATCH THE OIL, UNDO THE BOLT IN THE LOWER FORK LEG, AFTER ALL THE OIL HAS BEEN REMOVED, PULL DOWN ON THE FORK TUBE IF THIS PULLS OUT OF THE LEG THEN YOU CAN COMPLETE THE JOB QUITE EASY, REMOVE DUST SEAL, CIRCLIP AND OIL SEAL, THE LATER WILL BE QUITE TIGHT IN THE LEG, WHEN YOU EASEMBLE THE FORK YOU WILL HAVE TO UNDO THE TOP FORK NUT TO REPLENISH TTHE OIL

Sep 17, 2010 | 1999 Honda CBR 900 RR Fireblade

1 Answer

How to replace the fork seals on a 2003 harley davidson fatboy


If you ask this question YOU should not be doing it! but your *** on the seat not mine.
Remove ...........front wheel, front fender,top fork cap and loosen lower triple clamp bolts under head light cover, forks are now out!
Remove 6mm bolt at the bottom of the fork leg and drain oil,remove dust seal and wire clip, now remove the upper fork nut (the spring will jump out at you).Pull the leg and tube away from each other, the old seal will stay on the tube..clean and reassemble driving NEW seal down into place with wire clip.....refill with oil

Mar 31, 2010 | 2003 Harley Davidson FLSTFI Fat Boy

1 Answer

How do u disassemble forks


Here is a diagram of your forks:
http://216.37.204.203/Yamaha_OEM/YamahaMC.asp?Type=13&A=140&B=28
Assuming you have already removed your fork cap, you will need to remove the clip # 5 and the bolt # 18 then in a slide hammer type action, pull the upper tube out of the lower tube. There is a washer underneath the fork seal that will pull the fork seal out with the upper tube, so you have to compress the fork tube, then give it a good yank to pull the seal and separate the tubes.

A couple of tips here. First, to loosen the fork cap, loosen the top triple tree pinch bolt at each fork leg before removing the forks from the bike, then loosen the fork cap. You don't have to take the cap off at this time, but break it loose. It is very difficult to hold the fork tube and prevent it from turning once the fork is off the bike and out of the clamp. It is much easier to break it loose and leave it finger tight before dropping the forks out of the triple clamps. The key thing to remember is loosen the pinch bolt before attempting to loosen the cap. The pinch bolt applies extra pressure to the cap and can complicate the process of loosening the cap if left tight.
The other tip would be to use a 3/8" air impact wrench to loosen the allen bolt in the bottom of the fork leg. The internals will want to spin if you try to do it by hand.

Oct 03, 2009 | 1994 Yamaha FZR 600

1 Answer

Front fork seals need replacing Honda vigor FX650


hi non usd forks are ok thers a allen key bolt at the bottom of the fork leg would be wish to change the fork guilds too thr fork seals can be prized out with a screwdirver carfully

Jun 24, 2009 | 2000 Honda Vigor FX 650

1 Answer

How do i dismantle front forks to replace the oil seals


You just needed to.... remove front wheel, support bike on something, undo retaining bolts on forks, tap out fork legs from the top, using a soft mallet. Take out fork seals with a seal pick, (halfords) Replace old seal with new seals, in reverse order) sliding over the fork leg, tapping into place. Then put replace forks etc in reverse order (from dissassembly). Hope this helps

Feb 21, 2009 | 1992 Honda CB 750F2 Seven Fifty

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