Forks....I need help!

[xsRick]

In need of front fork experts help.

First... I'm not sure what I have. I know they are later model as they are 35 mm OD tubes. The confusion comes with the inside pieces not matching what the manual shows. The manual does not show the extra spring.
Second... The damage on the lower portion of the cylinder (the part cylinder fits into) is it critical?

 

[arcticXS]

That short spring on the damper rod is a top out spring, I believe standard from 78 onwards. Definitely an upgrade. The scoring on the conical sleeve should not cause much problems either. I guess you could just clean it up with a fine file and emery cloth.

 

[arcticXS]

Btw, as far as I lnow, that tapered alloy sleeve on the damper rod is for increased compression damping at the very end of the stroke. To prevent hard bottoming out. That mark makes me suspect that the corresponding sleeve at the bottom of the fork tube may have been installed upside down.

 

[AUTOMAN]

Cone damage from bottoming out HARD multiple times.

 

[xsRick]

okay thanks for your input. I'm trying to source another set now. There seems to be a couple of other small pieces missing as well. Not sure how this bike road in its day

 

[5twins]

The diagram you posted looks to be of a '76 34mm fork assembly. The "tells" are the top of the damper rod, the long spring preload spacer (#19), and the caliper mounts on the rear of the lowers. '76 was the only year that the 34mm forks had the caliper mounts on the rear of the lowers like that. While the forks are apart, I recommend Minton modding the damper rods, it's basically free and helps.

 

[xsRick]

Thanks I'll look up "Minton mod"
Does anyone have a manual picture of a later version fork that shows all the internal pieces? 35mm tubes. (US not euro, if there is any difference)

 

[5twins]

Details on the Minton Mods are here in my post #60 .....

https://www.xs650.com/threads/200-special.51454/page-3

 

[5twins]

Partzilla has pretty good exploded parts diagrams .....

https://www.partzilla.com/catalog/yamaha/motorcycle/1978/xs650se/front-fork

 

[arcticXS]

Partzilla has pretty good exploded parts diagrams .....

https://www.partzilla.com/catalog/yamaha/motorcycle/1978/xs650se/front-fork

I thought there was a bushing or sleeve held by an internal snap ring at the bottom of the fork tube, that the damper tube/ top out spring would hit when the fork is fully extended. Or is that a welded in part on these fork?
( I may be confusing RD forks, or even some Suzuki forks with the 35 mm XS forks here)

 

[5twins]

Only the '77 tubes have that removable bushing at the bottom of the tube. '78 and later tubes had it "crimped" in place .....

 

[xsRick]

Great pic! that helps a lot.
Thanks

 

[xsRick]

Details on the Minton Mods are here in my post #60 .....

https://www.xs650.com/threads/200-special.51454/page-3

great info
Thanks