I near had a heart attack when you grabbed that pair of slip joint pliers and grabbed the fork shaft.

I like the fact that you don't always know the answer, but nevertheless keep at it till you do. I like that, gives you humility...

I am in the process of re assembling the forks of a 1978 TT. I found your assembly easy to follow.

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.

Heroic. Could I cut a socket to make my own fork leg removal tool?

great vid. are using silicone gasket around the rubber seal?

@mostlymotorcycles.

3 жыл бұрын

Yes, to help seal the imperfections in the aluminium.

Don, what type of rechroming was made on your stamtchions? Hard chromium plating? how much did you pay more or less on each?

@mostlymotorcycles.

3 жыл бұрын

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.

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!!

@mostlymotorcycles.

3 жыл бұрын

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.

@martystalnaker1476

2 жыл бұрын

@@mostlymotorcycles. ATF works like a champ. I've had "many" XT's and TT's over the years, ATF is all I use now for trail and flat track.

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.

@mostlymotorcycles.

3 жыл бұрын

No race, just the slide bushings

What type of sealant are you using before you put the seals in. I just rebuilt the ones on my bike and can’t seem to find anything

@mostlymotorcycles.

3 жыл бұрын

just a black silicone. Nothing fancy as its not exposed to any heat.

@HoldFastMotoGarage

3 жыл бұрын

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!!

Seems so different than all other forks, where you use the stanchion as the slide hammer to remove the seals. Are XT500 forks that different?

@mostlymotorcycles.

4 жыл бұрын

Tubes are the same diameter top to bottom. so no slide hammer action.

@charlesmattina3787

4 жыл бұрын

@@mostlymotorcycles. I guess i will try seal removal the old fashioned way - self tapping screw, vice grips and tapping action with a hammer.

Did you use the same springs?

@mostlymotorcycles.

4 жыл бұрын

yes, old springs still good.

@jamespolucha6911

4 жыл бұрын

I have a front end off a 1979 Suzuki rm and was thinking of putting it on my TT500,what do you think? Just stay with the original or swap it out?

Got a link or size of those rear shocks?

@mostlymotorcycles.

4 жыл бұрын

kedopartsaustralia.com/ Couple of different options available.