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Topic : Thunderbike Thunderbird extended fork cap kit fitting
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 surfing72 
Set
Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 23 Oct 2012 - 07:37   Post title : Thunderbike Thunderbird extended fork cap kit fitting
 
Well I had thoughts of raking my bike but was concerned that this would stuff up the handling of the bike. I also thought about lowering the rear end but was concerned that I would scrape out when 2 up as I mostly am. The bride freaks out every time I'm leaning into a corner and the pegs scrape so after a little research I decided on the Thunderbike Thunderbird extended fork caps. i figured that this would raise the front end providing more ground clearance (less peg scraping) and give the illusion that the rear end was lower with a longer fork length / rake.. So here is the instruction and result.

Time: 1 hour

Tools: allen keys, rubber mallet, socket set.

Difficulty rating: easy with 2 blokes

Music: AC/DC Back in black

Beer: Tooheys new

Step 1. Loosen the fork clamping bolts on the top yoke and loosen the fork cap. Don't remove at this stage.


Step 2. Jack the the front end of the bike off the ground to fully extend he forks.

Step 3. Remove the original fork caps keeping pressure on them as the release.


Step 4. Use original O ring from original fork cap. You can see the difference between stock and thunder bike. This part compresses the springs and extends the forks.


Step 5. Fit new fork caps with a mate so one person can keep downward pressure whilst the other takes the thread up.


Step 6. Loosen bottom yolk and indicator clamps

Step 7. Slide fork tubes down until flush with top yoke.

Step 8. Tighten up all yoke and indicator clamps

Step 9. Add new brake line spacers and extended bolts below lower yoke.

This is not a dramatic mod but is cheap, easy and quick. Job done.


The only problem I have encountered is that the fork tubes are slightly scared from the original clamping. I have polished these scars but they are here to stay.


I had a quick test ride and the bike seems to have better ground clearance and doesn't handle any different. Its leans a little more when on the side stand which is not a bad thing and is noticeably higher at the front for me but not so much for mates.



 
Dan
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 magpie 
Jupiter
Reg. Date : 12/02/2011
Posts : 1,507
Location : NSW, Australia
Posted : 23 Oct 2012 - 09:31   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 

Dan,
Where did you buy the kit and how much was it ?
Thanks mate !

Magpie


 
Magpie - "I dream of a better world.....where chickens can cross the road without having their motives questioned "
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 surfing72 
Set
Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 23 Oct 2012 - 20:22   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: magpie)
 
Hey Magpie,

I grabbed these off ebay. You can also by direct from Thundebike online. they are based in NZ.

Oder details:

Triumph Thunderbird 1600/1700 Preload & Ride Height Fork Cap Kit ( 261113025354 )

Paid on 14-Oct-12 AU $155.00 AU $10.00 1 AU $155.00
Standard delivery from outside AU
Estimated delivery: October 24 - October 30, 2012

Cheers Dan

 
Dan
 Author 
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 fab 
Thor
Reg. Date : 12/10/2009
Posts : 2,515
Location : wyong, nsw, Australia
Posted : 23 Oct 2012 - 21:43   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: magpie)
 

magpie wrote:

Dan,
Where did you buy the kit and how much was it ?
Thanks mate !

Magpie


hey magpie, you have to actually lean while at speed to need these

 

Remember, soft cocks hang around all life long, hard ones come and go

ahh f**k im deep
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 rabbi 
Chaac
Reg. Date : 28/02/2012
Posts : 926
Location : Geelong, Victoria, Australia
Posted : 24 Oct 2012 - 07:52   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
Good instructions there Dan, I fitted these caps a little while ago and the improvement in cornering clearance is well worth the investment.

I found putting a bit of oil on the cap threads made it easier to screw them in.

My fork tubes also have the clamp rash from the original position, I put a leather tool bag there to hide it some.

I see you didn't fit the brake manifold packers/thick washers, any reason.

Sometimes whilst drinking a cold ale and admiring my bird (the one that doesn't nag) I think maybe fitting shorter rear shocks might help improve it's looks, sort of more chopperish style.



 
"Thinking is the hardest work there is, which is probably why so few people engage in it"
Henry Ford
Post edited by rabbi on 24 Oct 2012 - 07:56
 Author 
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 surfing72 
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Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 24 Oct 2012 - 08:08   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: rabbi)
 
Yeah mate I too added oil to the thread to make things happen easier. Nothin like a bit of lube to make things happen if ya know what i mean.

I might still consider the lower rear springs like you. I reckon that would cosmetically balance the bike. I once read an article on a bike that I thought was great. It was titled - Long Low and Wide... Thats how a cruiser should look but we have to be able to ride them to.

Dan

 
Dan
 Author 
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 magpie 
Jupiter
Reg. Date : 12/02/2011
Posts : 1,507
Location : NSW, Australia
Posted : 24 Oct 2012 - 08:13   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: fab)
 
Jamie ,
Ouch , you're a cruel bastard
But we all buy and have things we don't use as to how they were they intended....
you have a penis

Magpie


 
Magpie - "I dream of a better world.....where chickens can cross the road without having their motives questioned "
 Author 
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 surfing72 
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Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 24 Oct 2012 - 08:29   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: magpie)
 
I was waiting for the come back Magpie..........

 
Dan
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 Nashville 
Set
Reg. Date : 08/04/2012
Posts : 98
Location : Zuerich, Switzerland
Posted : 24 Oct 2012 - 18:36   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 

...
Time: 1 hour

Tools: allen keys, rubber mallet, socket set.

Difficulty rating: easy with 2 blokes

Music: AC/DC Back in black

Beer: Tooheys new

Your great!



 
Saor Alba!
 Author 
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 rabbi 
Chaac
Reg. Date : 28/02/2012
Posts : 926
Location : Geelong, Victoria, Australia
Posted : 24 Oct 2012 - 21:38   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: magpie)
 
Geez when you see quotes like "Nothin like a bit of lube to make things happen if ya know what i mean." and " Long Low and Wide" with " you have a penis", it make you wonder what goes on at these Aussie Flockings or is that floggings?


 
"Thinking is the hardest work there is, which is probably why so few people engage in it"
Henry Ford
 Author 
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 magpie 
Jupiter
Reg. Date : 12/02/2011
Posts : 1,507
Location : NSW, Australia
Posted : 25 Oct 2012 - 02:23   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: rabbi)
 

Rabbi,
All above board at the meetings I have been to.....not sure on the ones you attend though
I think it's just your mind is below your belt buckle !

Magpie


 
Magpie - "I dream of a better world.....where chickens can cross the road without having their motives questioned "
 Author 
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 fab 
Thor
Reg. Date : 12/10/2009
Posts : 2,515
Location : wyong, nsw, Australia
Posted : 25 Oct 2012 - 04:40   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: magpie)
 

magpie wrote:

Jamie ,
Ouch , you're a cruel bastard
But we all buy and have things we don't use as to how they were they intended....
you have a penis

Magpie


actually i have been told i must have two dicks,because they reckon i cant be that stupid with only one

 

Remember, soft cocks hang around all life long, hard ones come and go

ahh f**k im deep
 Author 
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 magpie 
Jupiter
Reg. Date : 12/02/2011
Posts : 1,507
Location : NSW, Australia
Posted : 25 Oct 2012 - 07:06   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: fab)
 

Your underpants fit you like a glove.....you have five dicks

Magpie


 
Magpie - "I dream of a better world.....where chickens can cross the road without having their motives questioned "
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 shagrat57 
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Reg. Date : 14/12/2011
Posts : 393
Location : Totton, Hampshire, United Kingdom
Posted : 25 Oct 2012 - 11:23   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
This is just what I'm looking for (more ground clearance), but my question is, will this modification work with other beers and music? I only have Fullers ESB in stock, and am partial to a bit of Crazy Cavan or Hillbilly Hellcats rather than those noisy AC/DC chaps

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 surfing72 
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Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 25 Oct 2012 - 20:24   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: shagrat57)
 

shagrat57 wrote:

This is just what I'm looking for (more ground clearance), but my question is, will this modification work with other beers and music? I only have Fullers ESB in stock, and am partial to a bit of Crazy Cavan or Hillbilly Hellcats rather than those noisy AC/DC chaps


Mate I can't see this being a problem however in this case I would allow 3 hours to complete the job.

 
Dan
 Author 
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 mat1600 
Thunderbird
Reg. Date : 06/03/2010
Posts : 8,596
Location : Bridlington, Democratic Independant State of Yorkshire, United Kingdom
Posted : 25 Oct 2012 - 23:57   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 

surfing72 wrote:

shagrat57 wrote:

This is just what I'm looking for (more ground clearance), but my question is, will this modification work with other beers and music? I only have Fullers ESB in stock, and am partial to a bit of Crazy Cavan or Hillbilly Hellcats rather than those noisy AC/DC chaps


Mate I can't see this being a problem however in this case I would allow 3 hours to complete the job.


Give it five hours if you choose Timmy Taylors.

 
My first natural instinct is to breathe. My second is to evade tax's.


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 surfing72 
Set
Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 27 Oct 2012 - 20:34   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
Well I went for my first test ride yesterday with the lads and put the extended fork caps to the test. I had the bride on the back so nothing to extreme but can confirm better ground clearance and a more solid front end. I think this has sorted the front end out but the rear end is still bouncing around like a pogo stick so that will be next. One of my mates (Nux) has recently been converted and purchased a Bird so I was able to view both birds front on and observe any comparison. There is a noticeable height distance between the lower yoke and the top of the guard between the two bikes but no obvious difference side on. I must say that over the entire ride I only scabbed the pegs once and that was around a round about so that is expected. I experienced a few heel scrapes as usual but thats no problem as the bride can't here that. Anyway for the money I reckon there a good investment.
Dan



 
Dan
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 FTL40 
Jupiter
Reg. Date : 13/10/2009
Posts : 1,122
Location : massachusetts, United States
Posted : 27 Oct 2012 - 23:18   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
hows the bird hang with the M109

 
2010 tbird 1700 silver (fastest color) BC exhaust, BC airbox removal

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 surfing72 
Set
Reg. Date : 20/03/2012
Posts : 483
Location : Nth, New South Wales, Australia
Posted : 28 Oct 2012 - 08:45   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: FTL40)
 

FTL40 wrote:

hows the bird hang with the M109


Mate not a problem at all. recently did a 2500km ride with M109 and even though I was 2 up and he is 1800c i kept up or lead all the way. In saying that I couldn't believe how much attention the M109 gets. Every where we stopped people flocked to it. I think because the badges are removed and the shear size of it. The rear tyre is a 250 compared with the 200 cheese cutter the bird has.

 
Dan
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 Agent86 
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Reg. Date : 17/02/2012
Posts : 361
Location :  Australia
Posted : 28 Oct 2012 - 09:35   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
Yes a little more cornering clearance would be very welcome .

 
Artificial intelligence is no match for natural stupidity .
2012 storm, re - ground cams, ported head, power commander, short tors, high flow filter & Meerkat cat bypass..
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 Ozian 
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Reg. Date : 25/01/2013
Posts : 187
Location : Brisbane, Queensland, Australia
Posted : 24 Sep 2013 - 05:25   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: surfing72)
 
I just installed these on my bike and WOW, what a difference!! Front end definitely feels more stable and planted, especially during hard cornering. The extra clearance is very welcome and I feel much more confident tossing tossing the bike into corners or roundabouts (ok, as much as one can 'toss' a bike this size).

Installation wasn't too hard, even without an extra set of hands to assist with getting the new caps threaded. However, this is not a job that should be done alone if you don't visit the gym at least occasionally. Luckily my forks didn't have much marking at all after sliding them down and polished up nicely.

Now the front is sorted I'm really keen to get some better shocks on the back. This bike just keeps getting better and better!!!!

Ian
2011 Blue and White 1600, short TORS, Thunderbike fork preload caps

 
Cheers,
Ian
2011 Blue/white stripe 1600, short TORS + tune, Meerkat cross-over, Thunderbike fork caps, Hagon Nitros, tail tidy
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 Hornet 
Jupiter
Reg. Date : 05/05/2013
Posts : 1,294
Location :  United States
Posted : 13 Jul 2014 - 12:53   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Ozian)
 
I recently install the Hagon fork springs and getting the stock caps back on was a challenge. The Thunderbike extender looks like it will compress the springs even more and could be a pistol to install.

Any one running stiffer springs with these caps, is it advised?

 
You'll never be first but you might be next
2014 Commander

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 Rachael7 
Chaac
Reg. Date : 17/05/2013
Posts : 511
Location : Greenfield, MA, United States
Posted : 13 Jul 2014 - 14:01   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Hornet)
 
I'm running stock springs with the Thunderbike caps and I wouldn't want to go any stiffer, not unless you are a very heavy rider. The caps do two things: they allow the fork tubes to slide down through the triple clamps an extra 10mm, which directly translates to ride height. They also increase the spring preload, by having an extended portion that sticks down into the fork tube. If you only want the spring preload, you can get it easily and near free, by just changing the length of the preload spacer that is in the fork. You could easily make a new preload spacer out of electrical conduit or exhaust tube - it's just a straight piece of thin-walled steel tube about 25cm long. If you want the extra length on the tubes to increase the ride height though, the Thunderbike caps are the way to go for sure. And finally, if you wanted that extra fork length, but without the extra preload, you could use the Thunderbike caps and easily cut down your preload spacers (or just make shorter ones) to keep the same spring preload.

 
2012 Thunderbird 1600, Short TORS, Triumph performance filter, TORs tune, Longhaul solo seat, Highway Hawk tubular solo rack, Dart flyscreen, engine bars, highway pegs, Clearwater Darla driving lights, custom flash-to-pass switch, Hagon 2810 rears, Thunderbike fork caps, Custom rear sets
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 Hornet 
Jupiter
Reg. Date : 05/05/2013
Posts : 1,294
Location :  United States
Posted : 13 Jul 2014 - 18:14   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Rachael7)
 
Good info Rachael, I was looking at these to adjust ride height a bit and was thinking it would require cutting down the spacer since I've gone to the stiffer Hagons.

 
You'll never be first but you might be next
2014 Commander

Post edited by Hornet on 13 Jul 2014 - 18:14
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 davetac1 
Thunderbird
Reg. Date : 06/09/2010
Posts : 8,379
Location : Haverhill, Ma., United States
Posted : 13 Jul 2014 - 20:39   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Rachael7)
 
I will be installing a set of those Hagon front springs directly,and since you've already done it on your Bird,is there anything I should be aware of???? Thank you. Dave!!!

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 davetac1 
Thunderbird
Reg. Date : 06/09/2010
Posts : 8,379
Location : Haverhill, Ma., United States
Posted : 16 Jul 2014 - 16:20   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: davetac1)
 
Well I finally swapped my stock shock springs for the Hagon springs alittle while ago,but wasn't able to road test it cause it's pouring out.The job took me just about and hour to do,but I did NOT change the fork oil either.I just added what was needed[via the fill level procedure explained in the SM] to replace the oil that was on the springs,tubes,and flat washers.The front end sets a little higher and still has a slight dive to it when ya apply the hand brake,but nothin like it was before. I won't know just how good [or bad] the ride is until I drive it.I'll let cha know!!

Update: 3 or 4 hours have now passed since doin the job.It's stopped rainin and the roads are dry,so I took her out for alittle road test.I found the bumpiest road I could and put her thru her paces,within reason of course.All I can say is,it's a different scooter.The ride is slightly harsher,[which should soften after some miles] but overall performance is definitely an improvement.

I can't believe I actually did somethin "RIGHT"! Not bad for a DUMB POLOCK!!. WHADAYA THINK???? Dave!!!

Post edited by davetac1 on 16 Jul 2014 - 20:02
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 Leethal 
Zeus
Reg. Date : 24/01/2011
Posts : 6,435
Location :  Australia
Posted : 16 Jul 2014 - 22:21   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: davetac1)
 
Dave how did you measure the fork oil level with the forks still intact?

 
Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Hagon Nitro shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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 davetac1 
Thunderbird
Reg. Date : 06/09/2010
Posts : 8,379
Location : Haverhill, Ma., United States
Posted : 17 Jul 2014 - 03:56   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Leethal)
 
With the springs, tubes,and flat washers removed from the forks,and both shocks fully collapsed [ya let the front end down VERY GENTLY until they bottom],I measured 106mm [4 3/16 inches] from the very top of the fork tube to the oil level.This procedure and oil level is per the Shop Manual. I used a 12 inch rule with a piece of electrical tape across the rule at the 4 3/16 inch mark, slowly sliding it down into the tube until I was at that marked measurement,then removed it to see if there was oil showing on the very bottom of the rule.If there happened to be too much,from an over fill,I would have used my battery bulb to suck out alittle ,then check it again.If I didn't have enough,which was the case for me[the springs,washers and tubes were saturated with oil when I removed em,so a little oil had to be added],I added just a bit into the tube,checked it again,repeating that until the oil level was correct.Then I did the same on the other tube.

Now if ya don't happen to have any 10 weight shock oil handy ,light hydraulic oil,which is basically the same oil,will work just fine.I've been usin it for years without any problems.Was my procedure clear?? Questions???

Now I also learned somethin else today!!Since day one,when I bought this machine brandy new,the front suspension NEVER felt right to me.It was TOO soft,especailly when goin over a rough road surface,sometimes even bottoming out on small bumps,and would drop substantially on hard brake application,and more then I cared for on light brake application. I even complained about it to the dealer shortly after buying it.Of course their answer was " THEY ALL DO THAT". The road test I gave it this afternoon was just a short ride to check for leaks and or any problems that may have been caused by me. [I know you'll probably find this hard to believe, but I do fuck up every now and then,but more then,then now ]The real test came tonight when I ran the machine for 70 miles over some bumpy roads which she performed admirably on.

Anyways,all those problems are now GONE and it's an entirely different machine.What I should have done right out the gate,when she was brandy new, was change the fork springs, because doing that back then would have made a MAJOR IMPROVEMENT to the ride,stopping power,and handling of this machine.So my point is,if I had this problem,other Tbirds must also have had the problem.Now my factory springs were NOT broken or damaged when I removed em.The new springs [Hagon Progressive Springs,bought from Fast Eddy],used the same guage wire,were progressively wound on one end, were a couple inches longer then the factory springs,but gave me no problem getting the top caps screwed back into the top of the shocks due to the extra length.But she NOW has a totally different [improved] feel in the front suspension and I'm liking the machine more and more.

Now regarding that stupid belt!! Dave!!!

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 Leethal 
Zeus
Reg. Date : 24/01/2011
Posts : 6,435
Location :  Australia
Posted : 17 Jul 2014 - 05:37   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: davetac1)
 
I've just done a fork oil change with forks removed but thought the tubes had to be vertical to do the measurement, which is why I asked the question.

 
Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Hagon Nitro shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
 Author 
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 davetac1 
Thunderbird
Reg. Date : 06/09/2010
Posts : 8,379
Location : Haverhill, Ma., United States
Posted : 17 Jul 2014 - 12:23   Post title : Re: Thunderbike Thunderbird extended fork cap kit fitting (Re: Leethal)
 
Actually Triumph does offer a tool [103 bucks USD] for the purpose of checking the oil level and or extracting the old oil WITHOUT removing the forks.But I don't have one.So I made due with what I had.But the level measurement I gave ya is correct and is listed the SM which is where I got it from. Dave!!!

Post edited by davetac1 on 17 Jul 2014 - 12:26
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