fork seals 2001 Trophy 1200 - Triumph Forum: Triumph Rat Motorcycle Forums
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post #1 of 9 (permalink) Old 07-27-2019, 11:56 AM Thread Starter
Production 125
Main Motorcycle: 2001 Triumph Trophy 1200
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Location: MIlk River, Alberta, Canada
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fork seals 2001 Trophy 1200

I have changed the oil and dust seals on the front forks. Now the inner tube ( stanchions or fork tube ) are stuck open. I cannot slide them into the outer tube or fork slider. How can I get them to slide so that I can put the correct amount of fork oil in?
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post #2 of 9 (permalink) Old 07-27-2019, 11:12 PM
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Did you assemble the bush,washer,seal, circlip and dust shield into the outer tube and then attempt to install the inner tube?

All that should be installed after the inner tube is installed and secured in the outer leg. - Pete
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post #3 of 9 (permalink) Old 07-28-2019, 12:20 PM Thread Starter
Production 125
Main Motorcycle: 2001 Triumph Trophy 1200
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Location: MIlk River, Alberta, Canada
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Yes I had a retired Triumph mechanic do this. he lives in a differrent city. When I left his place they were working . When I got home and tried to assemble the last part then I could not compress the tubes .
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post #4 of 9 (permalink) Old 07-28-2019, 01:52 PM
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What are you referring to as "the last part"? - Pete


https://www.worldoftriumph.com/parts...ck/304710-0-2/
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post #5 of 9 (permalink) Old 07-29-2019, 12:06 AM Thread Starter
Production 125
Main Motorcycle: 2001 Triumph Trophy 1200
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He checked the bushings on the inner tube and then secured it in the outer leg again using the air impact wrench. He then assembled the bush washer oil seal,circlip and the dust seal. The inner forks or tubes then able able to be compressed into the outer tube.
I put them in the trunk and several days later I took them out of the trunk and they would not compress.
If they would compress all I had to do was compress them ,put in the oil then put in the springs,spacer and the top bolt. Then just reinstall them on the bike.
I have tried to heat them to loosen them up and that did not work. I have put a piece of wood on the top tube and hit it with a hammer -that did not work. I have moved the outer tube around hoping that -that would do it-with no luck.
There must be something binding.
Should I loosen the damper rod and the damper rod bolt a bitin the hopes that it will free itself? I do not want to use a sledge hammer. Perhaps the air impact wrench tightened damper rod to much.
Or should I just start all over and remove the oil seal ?
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post #6 of 9 (permalink) Old 07-29-2019, 11:55 AM
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It sounds like the seal area was put together just fine. Very odd. Are the fork tubes jammed in both directions? Number 11 in the parts blow-up above is the damping cylinder and is the part secured by the bottom bolt. I think something is amiss in this area and not the seal area. I'd say your best course is to take it apart and inspect for correct assembly. Once you get the bottom bolt out of the lower tube the the inner tube should be free to slide. Once the dust shield and circlip are removed one or two quick yanks up on the inner tube will safely pop out the seal and top bushing. Do you have a manual? The blow-ups can look a bit strange but everything is very logical once you get in there. The seals are not in very tight I made a driver from a piece of PVC pipe. - Pete
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post #7 of 9 (permalink) Old 07-30-2019, 11:52 AM Thread Starter
Production 125
Main Motorcycle: 2001 Triumph Trophy 1200
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Join Date: Jul 2019
Location: MIlk River, Alberta, Canada
Posts: 5
Yes they are jammed in both directions.
I have the Triumph Service manuel and the Haynes mauel for triumph triples and fours for 1991 to 2004 and as many other articles I could find.
I will loosen the damper rod and see if that frees it up. If not as you suggest I will start over and put in new seals .

Thank You for your help.
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post #8 of 9 (permalink) Old 07-30-2019, 12:37 PM
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If it does free it up I would not be tempted to cinch them down again and hope fore the best. I think something has been put together wrong in there that has nothing to do with the seals. I think there is a good chance that once the bottom bolts are out the whole assembly will slide out of the lower tube. You'll still have to give it a good yank to dislodge the seals though. - Pete
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post #9 of 9 (permalink) Old 08-04-2019, 02:24 PM
World SuperBike
Main Motorcycle: 2001 Trophy 1200, T509
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Other Motorcycle: Norton Commando MK 3
Extra Motorcycle: 1968 BSA Thunderbolt
Well, did you ever get those things apart? - Pete
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