Great and informative vids - thank you! I have a 78 XT500, owned it since 1980. I had her restored once, 10 years ago and have not been totally happy with her ever since and am looking to do an engine rebore as it has a bit of piston slap. Also, I need to have the carb cleaned and rebuilt as well as the tank as it has been running rough, probably due to crap in the fuel system/carb/tank. I'm building up to attempting it myself and your videos have given me a really good look at what is involved. Cosmetically she is beautiful but still needs work. I'm a Brit based in Italy so also there is a bit of a language barrier when trying to get anything technical communicated so perhaps better to do it myself. Thanks again - I've learnt a lot from you, so far!! Keep them coming!! Good luck with the heat out there!!
The easy way to remove the bottom bolt in the fork lower is to crack it loose first, before you disassemble the top end. The spring tension keeps the damping rod from turning. Once you’ve got the bolt almost out, remove the top fork bolt, spring and drain the fork leg...then screw out the bottom bolt, it’ll come out easily.
I use an industrial chroming business in Perth that rechromed hydraulic cylinder shafts. They did an excellent job but it wasn't cheap $400 per leg. from what I have found out the 78 model used a unique fork leg type that discontinued in 79. From 79 on I believe new ones are available.
Thanks for this vídeos! On minute 7.07 of te video you start to get the slide bearings out. My question is before the slide bearingvthere was a circlip and before the circlip did you find a race? I did not see you removing it nor getting it back on. Mine has it. 1976. XT500C.
Very nice video series!! I have a 79' TT500 and a 76' XT500. Both family heirlooms passed down to me. I will be rebuilding their forks soon, and Im curious what weight oil and how much did you put in the forks? Thanks and keep up the good work!!
10 weight standard quantity for 78 xt was 230cc. I believe the tt had different weight and volume so you'll have to research that. Thanks for the positive comments.
DonYourHelmet thanks for the reply. I found blue type sealant in the forks when I pulled the old seals out. Then I put about 10 psi in it and all the oil leaked out around the seals. I’ll try this thanks!!