82 xj650 fork assembly

hey guys, need a little help. I tore my forks down to rebuild them. I got new springs, o rings and seals and things but the website I was just using with the diagram of them went down. I just had it open too. But anyways I’m a little nervous of the order of parts. Does anyone have a good assembly picture? I’ve been just trying to go off the generic Yamaha one for parts but I’m not 100% sure I got them right. Thanks for all the help.

 

from manual

 

Thanks. I was having the confusions with the sleeve part. Wasn’t sure the order on there. Also I guess the spring seat is one piece with the stopper ring. As mine only has that one piece.

 

spring seat is a separate part
maybe @chacal sells them through www.xj4ever.com

 

The stopper ring is the snap ring that hold the seat in, diagram not very clear there.

 

Ah. I see it now. I have it correct. Thanks for the help guys.

 

There are several fork rebuild threads in the DYI section.

 

These incredible 3-D renderings of the inner workings of a forking system gives a great visualization of the internal components (it is based on the 1982-83 XJ650 Maxim forks):



and

http://xjbikes.com/forums/index.php?threads/29616

 

I saw the 3D stuff but I couldn’t find the spacer on it. Same with the builds. I saw lots of info just not where the spacer went. I have it figured out now. Thanks for the info.

 

Now that I know where it goes I see it in the 3D pictures. Just couldn’t put all the pieces together in my head the last few days.

 

@XJ550H I just read the carb breakdown/clean procedure on xj4ever.. Pretty damn good. I had no issues jetting my Thundercat (YZF600R- owned two but only modified one) so this shouldn't be too bad on my 83' xj550, although the float levels were not adjustable on the Thundercat. Thanks for keeping in good touch on here. I've noticed.

 

@Somedayrockstar I'm about to overhaul and replace front springs on my 83' xj550. I've never done this before. Do you recommend a particular stand? I was just gonna use a chainfall to suspend the triple tree. Maybe I should get a motorcycle jack? Thank you for asking the questions and taking on the work.

 

center stand the bike first. then get those plug caps off of the top of the fork. you will have to loosen the top clamp on the triple tree. when you get the clip out and clean the top opening in the tube cover it with a rag and push down on the fron tire and the capplug will rocket out. be very carful when doing this. also be very carful when removing clip as the cap could come out before you expext it to.

remove drain plug at bottom of fork and pump the fluid out by pushing down on the front end.
if it is a seca you will have to remove front tire for the next step .the allen head bolt you will need a little heat to loosen the loctite.

myself I just bolt the fork tube down on a sheet of plywood to remove the allen head bolt.
I use the fender mount holes

 

I got a Maxim according to the title. I'll double check the VIN and update sooner than later. Lucky for me, the previous owner did a complete frame strip and paint and rewire. Engine was rebuilt and new clutches in trans. The airbox was replaced with a high flow cone filter on each carb so the carb assembly was a breeze to get out. I ordered new intake boots since they looked a little cracked but they are not cracked all the way through. So I might hold onto the news until I get a surge. Throttle bodies look really in sync. I might get away with leaving everything whole and just remove the bowls. Gum cutter works wonders. I want the old seat design back so I can take my lady for a spin. It currently has a custom cafe racer setup with rear cover that is a bit obnoxious. Tank is f***ed up as I found a leak after noticing a small crack in the finish. Turns out it was a bunch of bondo over a lead repair over a gouge in the side of the tank from a lay down possibly. The bondo was used on both sides to make the tank look bigger and they did a great job with the finish coats and mounting the Yamaha placards. I chiseled away the bondo, torched out the lead and mig welded a steel plate to properly repair the tank. Then water tested and for good measure epoxied the weld seams. I cant find a new fuel sender/level unit but got a new petcock and gaskets. Tank needs a good stripping as the red kote is all flaked up and shit. No use for redkote I think. I'll be posting pics and progress eventually. Thanks for the fork info.