How-To: Rebuild XS650 Forks / Install Lowering Kit

Guys, if I want to lower my SR500 by removing the top 1.5" spacer, can I just put it down on the bottom on the damper? Swap positions?
 
Guys, if I want to lower my SR500 by removing the top 1.5" spacer, can I just put it down on the bottom on the damper? Swap positions?
No. A "lowering spacer" needs to fit snugly on the outside of the damper rod, just below the damper rod piston. The upper spacer does not have sufficient wall thickness for this.
If I was going to lower an XS/ SR fork by that much, I would try to design/ make a spacer/ top out spring combination. And make sure it does not interfere with oil flow.
 
Great post. I just ordered the 2" spacers from Hugh.
Questions:
1) are there 2 holes in the 2" spacer, one as oil passage and one as the set screw? Hard to tell from the pictures.

2) If I use the 2" spacer, full length, can I take out the top spacer and use the extra 1/2" of spring (that would otherwise need to be cut off) as pre-load? is it easy enough to get that cap back on?

3) can anyone recommend a good fatty commando style gator for this 2" lowering job? Often the gator bellows get mashed and it looks obvious when using stock height gators. These are 35mm on one end and 55mm on the other and about 5-6" tall
 
I don’t have a welder, so did the same thing with an M10x20 using two nuts, a lock washer, and red lock-tite. Worked like a charm!
So, I did the same thing actually for a mid-eighties Yamaha 750 and the same "tool" worked for my 78E... miracle!

But further, with other bikes (e.g. Kawasaki KZ1000), I have had great success using this, rather than always trying to make a special tool, or use a piece of dowel and so on.

https://www.amazon.com/Original-Sel...cphy=9028243&hvtargid=pla-2281435178618&psc=1

BTW, I did not think this up, but read about someone suggesting it some time ago.
 
Hugh & Co., I got the 2" spacers. Thanks. (2 holes, no set screw) . I have an SR500 and my forks are the early type with the recessed cap nut 17mm hex (used a timing wheel puller screw top, fit perfectly and you use a crescent wrench on the part that sticks proud). I also have the stock 2" spacer on top. However, when I look down the tube, I dont appear to have the 2 flat sided damper rod that requires the 17mm socket mod. Could I have a combo of the later damper that requires the inserting of a Allen wrench end along with cracking the Allen wrench on the opposite side? This is odd because I have the top steel spacer. Is this an SR500 set up? I don't believe the guy I bought this from ever had these forks apart. Just looking to get these forks sorted tonight. Thanks.
 
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