How-To: Rebuild XS650 Forks / Install Lowering Kit

That does help cause I need to start somewhere. I'll start conservative since you can always cut more off and not the other way around :)
 
I have 34mm forks on my 76C.
They are apart and all of the pictures here do not show me what order the parts go on the damping? rod.
The Yamaha parts manual is hopeles.

Any ideas plse???
 
First off, this thread has been outstanding from a learning POV, and helped me reach the point I am at today...

So here goes... I was able to completely disassemble one of my forks (76' "early" spec). I hacked up a socket but found that I was not able to hold the damper very well. Rather than a 17mm socket, it looks like the top of the damper might be held better with what looks like a 10mm DIY socket apparatus. Here's what I found when I pulled everything apart.

I haven't had a chance to tackle the other fork tube yet, but definitely want to have a good solid grip on the damper when reassembling.

off topic: Holy smokes did the old fork oil smell! :eek:
 

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Is it possible to drill a new small valve hole further down? since the spacer will cover it. this would be a more simple route then to drill the spacer twice for valve hole and a set screw, and also more safe if that set screw comes loose and can block the valve hole anyway..
 

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This thread rocks! I used it last night when I tore down the forks on my 79. I didn't install Hugh's lowering spacers when I did it - I just did a straight up rebuild. I did install Hugh's solid riser bushings once I got it all back together. Can't wait to see how it rides!
 
So stoked to find this thread! it is awesome.
I just have one question apologies if it has already been answered or if it is an obvious answer. I have searched and have not found the answer myself yet.
But anyway.. I am about to rebuild a pair of forks. Early type 35mm style. They are currently being sent to me from a wreckers(don't have them in my greasy mits yet). I do not know what year model they are off. I need to replace or repair the tubes as they are pitted.

My question is: Are the tubes the same for the early and late model 35mm forks? and sorry second question, best place to find replacements?
Thanks in advance if anybody can help me out.

Pics from the seller attached, missing the pics from the top but they are the early type.
 

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Can anybody help me out with what I have here?
Bought these thinking they were a 77 early style 35mm set of forks.
On stripping them down they appear to have the early style cap and top end spacer but they seem to have the late style rod at the bottom. Are these a standard variation or a hybrid?
Thanks in advance
 

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They measure 35mm I haven't measured the length yet. I'm pretty sure they have been apart at some stage as the washer that seats in the top of the spring is missing on one.

Any idea if the mixed parts would affect the functionality or safety of these?
 
Have finished sprocket and spacers to fit to my RD400 18inch rear wheel
 

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You don't have to do a 100% strip down. The damper rods can remain in the tubes but the lowers have to come off. But, if you've never had them apart, it's best to pull everything apart so you can thoroughly clean all the parts. The forks accumulate lots of dirt and sludge build-up inside over the years. Since they don't get real hot during operation (like your motor), draining them doesn't flush all that crap out. You have to get inside there yourself and "swab" it out. I have a "special tool" for this. It's nothing more than a length of 1/4" rod with a small eye bent in one end. You thread a rag through the eye, wrap it around the rod, dip it in solvent, and have at it .....

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Great tutorial thanks. I am in the process of refurbishing my forks and will be buying the lowering spacers.
 
1975 XS 650B fork piston assembly.JPG
1975 XS 650B fork piston assmbly detail.JPG
1975 Yamaha XS 650B fork piston assembly photos. I'm posting these because the 3 piece (castellated fitting, small coil spring and retaining cup) are shown as a single piece and not exploded and illustrated in any of the shop manuals I've seen. If you loose track of order when disassembling your forks (as I did) you tend to pay more attention when doing the second one. Also, as noted above and in other postings, you will absolutely need a modified 10mm socket and about 20" of extensions to hold the top of the piston while removing and reinstalling the allen bolt
 
So stoked to find this thread!
I am about to rebuild a pair of forks. Early type 35mm style. They are currently being sent to me from a wreckers(don't have them in my greasy mits yet). I do not know what year model they are off. I need to replace or repair the tubes as they are pitted.
My question is: Are the tubes the same for the early and late model 35mm forks? and sorry second question, best place to find replacements?
Thanks in advance if anybody can help me out.

Pics from the seller attached,

22-04-2017 001.jpg

These forks are off a Japanese 80 3G5. 35mm

Can anybody help me out with what I have here?
Bought these thinking they were a 77 early style 35mm set of forks.
On stripping them down they appear to have the early style cap and top end spacer but they seem to have the late style rod at the bottom. Are these a standard variation or a hybrid?
Thanks in advance

Yes these are 35mm
IMG_1772.JPG

TX650 (4E3) Parts manual  074.jpg
The Part diagram is for a Japanese TX 80-82 4E3 35mm forks. These look to be the same as the 80 3G5.

The difference between the bikes.......... the 3G5 is a Special and the 4E3 is a Standard
 
I think the North American 650s were the only ones that got the adjustable top cap. The rest of the world got the plain cap and spacer tube.
 
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