MarJay's Project part Three: Triumph and Disaster

MarJay · But it's British! Joined: 15 Sep 2003 Karma :

Well, when you last left me the TT600 was on its way to being mended. All I had to do was rebuild the forks and I would be done.

Except... I found a large dent in one of the fork stanchions so I ordered some replacements from ABE. They came the next day and were of a reasonable price. The one downside is that there is a bearing inside the old fork stanchions that needs to be transferred to the new ones. On the new ones they are held in by a circlip.
The old fork stanchions are rolled over at the end to hold the bearing in.
https://www.bikechatforums.com/download.php?id=9394

This meant that I needed to break out my Dad's bench grinder! Very Happy

I'd been waiting for something to come along that I could use it on!

https://www.bikechatforums.com/files/benchgrinder.jpg

I attached it to the trusty workmate and ground the end off of the stanchion. Took a bit of doing but I got there in the end. I did both stanchions and re assembled the new stanchions.

Again with the assistance of my trusty workmate, I began to rebuld the forks.
https://www.bikechatforums.com/files/workmate.jpg

The right one went back together smoothly and without a hitch.

The left one went OK until I put the oil in. A small pool of oil began to appear beneath the workmate. I examined the fork carefully and came across this:

https://www.bikechatforums.com/download.php?id=9390

Needless to say I'm not best pleased. The brake caliper mount on the left hand fork tube has a hairline crack along its root. This is bad.

If I were to patch the leak I don't think I could trust the bracket to do its job so I think this means a new fork lower. Sad

So again, I leave you with an image of my lovely TT600 in a bit of a sorry state.

https://www.bikechatforums.com/download.php?id=9389
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

mchaggis · World Chat Champion Joined: 10 May 2004 Karma :

So far, almost so good then. Confused

That fork lower was the original one, wasn't it, so must have been damaged in the original crash? What else has been fixed since it was borked to begin with?

Oh well, keep at it. Thumbs Up

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Mmmm, Guinness
Discovering the delights of Hammerite and a 3/4" brush. Very Happy

Frost · World Chat Champion Joined: 26 May 2004 Karma :

Yes, damage like that could only come from a manufacturing fault or from the crash.

So long as the stansion and spring are allright i don't think the quality of the fork lower is too much of an issue. You might be able to pick one up cheap second hand or from a scrap yard. Definatly worth a look!

Bottom line is, nothing expensive is warped, a fork lower is annoying to have to replace, but you'll have a great bike afterwards and its not the most expensive of parts to have to replace Thumbs Up

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Given that the bracket is under compression when you are using the brakes it may not be that bad a problem, but I would not trust it

However, I dare not think how it was damaged. I would check the brake caliper for damage, and check the disk for being warped (not likely but possible if it has be clouted hard on the side), but most importantly check the front wheel spindle is straight.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

MarJay · But it's British! Joined: 15 Sep 2003 Karma :

The wheel spindle is straight, the brake calipers are fine as are the disks.

The weird thing is the damage that was there...

The cracked caliper mount, the dented (not bent) stanchions, and a heavily dented and warped yoke. Dunno WTF happened to the bike to get it in that state, but whatever it was it was nasty!
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

tgabber · Crazy Courier Joined: 03 Jun 2004 Karma :

I have to comment on the lack of proper protective kit while using the bench grinder...

Shocked

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"It's all about dislocating expectation"
Kawasaki KMX125 -> Aprilia RS125 -> Kawasaki ZZR600

MarJay · But it's British! Joined: 15 Sep 2003 Karma :

tgabber · Crazy Courier Joined: 03 Jun 2004 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

G · The Voice of Reason Joined: 02 Feb 2002 Karma :

MarJay · But it's British! Joined: 15 Sep 2003 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Cannot think how you would dent the forks without bending them, but it is quite easy to dent them when bending them and this is pretty much kills them as you cannot fix it by straightening them.

Entirely possible that they bend the forks and wreck the top yoke at the same time.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

Davo · Davo To The Rescue! Joined: 05 Apr 2004 Karma :

TiN · Pocket Tin Joined: 14 Feb 2002 Karma :

That's a bit of a downer mate, but I know how it feels...it was like that with the CBR...one minute the bike was almost assembled and "ready", then you spot another problem...

Well, it looks like an opportunity for a nice fork conversion then! Very Happy

...the ones from the new Speed Triple look nice... Wink

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TiN
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