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TR1 1981 fork cap  problems (Read 3441 times)
Evripidis
TR1 Board Junior Member
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Posts: 55
Gender: male

Bike: xv250
Re: TR1 1981 fork cap  problems
Reply #10 - 24.10.24 at 08:44:59
 
Hello all and sorry for the resurrection again.

I have a question before I engage on this job.

How is the cap/circlip removed. I never had a bike with such fork.

I know the asnwer must be in the service manual, I asking if there are any tricks for this.

Evros

 
 

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Anja-D
TR1 Board Senior Member
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carpe diem

Posts: 402
Gender: female

Bike: 1981 TR1. (5A8), modified with XV1100 (3LP) Eng.
Re: TR1 1981 fork cap  problems
Reply #11 - 24.10.24 at 12:45:25
 
Hello Evripidis,
I guess you want to remove the Cap to take out the springs inside of the fork-tube?

If it is so, remove the Steering bar to get enough space. Be careful , so that no Brake fluid escapes from the reservoir and perhaps damage other parts, e.g. your Fuel-Tank.

To remove the Caps it self you will need
 - a small Screwdriver with blade end, /(for slotted screws),
 - a Wrench Nut which fits to the Air Valve hex, and a suitable tool to get more distance for better workspace.
1. Take the wrench Nut assembly onto the hexagon socket of the air Valve
2. Puch down the Cap, enough so that the circlip inside is fully visible.
3. with the Screwdriver you can level out the beginning of the circlip. But be aware that the circlip is not jumping away. It it difficult to find it.
   It is a little bit tricky, but it will coming out.
4. Now let the plug (Cap) coming out by releasing pressure. If the Plug is not coming out at the first time, try again to push the plug into the Fork Tube and than release the pressure of holding down immediately. If necessary try it several times.
Reason could be some dirt inside, or a little bit of deformation of the grove of the circlip.

Regards Anja


 
 

TR1 seit 1982, die aktuelle seit 1988, schraube und fahre selbst
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Evripidis
TR1 Board Junior Member
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Posts: 55
Gender: male

Bike: xv250
Re: TR1 1981 fork cap  problems
Reply #12 - 24.10.24 at 12:55:06
 
Hallo Anja,

Thank you this makes sense now.

In reality I only want to replace the fork seals. The entire fork does not have to be taken apart, but I am afraid that I might damage the surface by trying to prise out the seal. I have done it before but I am afraid to do it on this bike.

Evros

 
 

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Anja-D
TR1 Board Senior Member
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carpe diem

Posts: 402
Gender: female

Bike: 1981 TR1. (5A8), modified with XV1100 (3LP) Eng.
Re: TR1 1981 fork cap  problems
Reply #13 - Yesterday at 12:03:51
 
Hello Evripidis,
one  at first. My Description belongs to the removing of the Fork-Tube-Caps (Imags No: 15/38) with the Air valve in it.

Do you want to change the Oil seals of the Fork?
If you want to go ahead with your scheduled Replacement, be aware not to scratch the inner Tube !!!

Primary, it would be better to take the Front Fork Units out and fix them on your bench.

I have attached to images with parts of the Fork Assembly:
8 /31 = Dust Cover
4/27 = Circlip of the Oil-Seal
3/26 = Oil-Seal

Regards Anja

 ETL_A044.jpg   ETL_A045.jpg     Pictures below may be scaled. Click links or pictures for original size Click here for all attachments  
 

ETL_A044.jpg
ETL_A045.jpg

TR1 seit 1982, die aktuelle seit 1988, schraube und fahre selbst
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