Front fork — disassembly (Triumph Rocket III)

0

Warning! Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

1. Remove the forks as described on page 14.9.

2. Secure the fork in a soft jawed vice, gently clamping it on the caliper mounting.

Warning! Clamping the fork by any point other than the caliper mounting may damage the fork. A damaged fork is dangerous and can cause instability leading to loss of motorcycle control and an accident.

Caution! When securing the fork in a vice, take great care not to over-tighten the vice, as this will cause damage to the fork.

Note: The fork seals can be renewed without removal of the damping cylinder. Unless removal of the damping cylinder is necessary, omit items 3, 11 and 12.

3. Unscrew the top cap from the outer tube.

Note: The top cap is not under spring tension.

4. Remove the fork from the vice and have an assistant stand it upright on the floor.

5. Fit tool T3880067 over the top cap. Position the two adjustable arms to the holes in the spring spacer. Screw in the arms until they positively engage in the spring spacer holes.

Warning! While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.

6. Using tool T3880067, manually compress the fork spring and insert the spring holder below the damper locknut.




7. Slacken the locknut, unscrew and remove the top cap. Recompress the fork spring to remove the holder.

Warning! While recompressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.

8. Remove the spacer, spring cap and spring.



9. Holding both the outer and inner tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all oil.

10. Return the fork to the vice, clamping it as before.

11. Separate the inner and outer tubes leaving the dust and oil seals in place in the outer tube.




12. Remove the damper rod locknut then insert the square end of tool 3990090-T0301 over the damper rod and engage the square in the damping cylinder cup inside the fork. Hold the hexagonal end of the tool to prevent the cylinder from turning while removing the damper bolt from the bottom of the fork.



13. Remove the tool, then the damping cylinder from the inner tube.



14. Using finger pressure, remove the dust seal from the outer tube.

(The source is located on the portal: «MotoInstruction.ru»)



15. Remove the circlip from above the seal.



16. Note the orientation of the seal lip then, using a soft-faced drift, remove the seal and collect the washer from below it.

Inspection

1. Inspect the inner tube for stone chips, scoring, scratches, excessive wear and any other damage. Renew the inner tube if necessary.

2. Inspect the spring for damage, cracks and deformation. Renew the spring if necessary.

3. Inspect all bushes and seals for damage. Renew any damaged items if necessary.

See this article in russian language

Front fork dust seal — inspection Kawasaki ZX6R/ZX600J (2000-2002)
Front fork — design description Suzuki DRZ 250 (1996-2007)
Front fork adjustment Yamaha FZ1 Fazer (2006-2015)
Front Fork Legs — Oil Change Honda CB 400 SF (1992-1999)
Replacing front fork oil Harley-Davidson V-Rod (2002-2006)

Article about repair motorcycles «Triumph Rocket III» (2004-2018): «Front fork — disassembly»: https://motoinstruction.ru/en/Triumph/Rocket/III/chassis/fsusp/111950 <a href="https://motoinstruction.ru/en/Triumph/Rocket/III/chassis/fsusp/111950">Front fork — disassembly</a> - article about repair motorcycles «Triumph Rocket III» (2004-2018) from section «Front suspension and handlebar». [url=https://motoinstruction.ru/en/Triumph/Rocket/III/chassis/fsusp/111950]Front fork — disassembly[/url] - article about repair motorcycles «Triumph Rocket III» (2004-2018) from section «Front suspension and handlebar».