Author Topic: 1977 xs500d fork tube cap  (Read 1412 times)

0 Members and 1 Guest are viewing this topic.

Offline Dave Walters

  • Jr. Member
  • **
  • Posts: 6
  • Karma: 0
1977 xs500d fork tube cap
« on: November 29, 2013, 09:04:43 PM »
I am rebuilding a set of forks off a 77 xs500d and I need to know the best way to remove this cap thing so I can get the the threaded piece to disassemble them.

#21 in pic


Offline CrouchyUK

  • Administrator
  • Hero Member
  • *****
  • Posts: 1033
  • Karma: 20
    • Brigg, Lincolnshire, UK
Re: 1977 xs500d fork tube cap
« Reply #1 on: November 29, 2013, 10:34:28 PM »
Welcome to the forum!

#21 is actually the rubber cap that tops it all off.  Do you mean the top seat #19 that holds the spring down?  It's not threaded- Circlip #19 holds it in position, so pushing down on the cap and removing the clip will dismantle.

It can be difficult- berniebee came up with a method using a wooden clamp and puller about halfway down this thread...

http://www.xs500forum.com/index.php?topic=240.msg3890#msg3890
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline guylr

  • Administrator
  • Hero Member
  • *****
  • Posts: 1171
  • Karma: 19
    • ATL in the USA
Re: 1977 xs500d fork tube cap
« Reply #2 on: November 29, 2013, 11:22:14 PM »
By far the easiest way is how we did it in the shops when the bikes were new. With the tube still in the clamps tighten down the crown pinch bolt more than it is at present. Take a drift or wooden dowel and hammer down on the cap. If you have the bolt tight enough the cap will stick down exposing the wire circlip. If the cap doesn't stick down then you need to tighten the bolt just a little more at a time until it does. Then use a pick to extract the clip and loosen the pinch bolt. Put a rag over the cap before loosening the bolt because sometimes they will pop out with some force and land on your nicely painted fuel tank.  :(

Works every time.  ;D

Guy
Now Retired Yamaha guy. Cut me and I bleed "Cinquasia Red"

Offline Dave Walters

  • Jr. Member
  • **
  • Posts: 6
  • Karma: 0
Re: 1977 xs500d fork tube cap
« Reply #3 on: November 29, 2013, 11:26:27 PM »
Thanks guys.

I am actually rebuilding this front end for a xs650 chopper.

I have a set of 12 over xs650 fork tubes coming.
Waiting to see what kind of end cap they take so I can put it all back together.