XBR 500 REBUILD

[guest288]

Now I know how to post pictures, I thought I'd show how I'm getting on with the XBR rebuild.

First, the powder coated frame: 



The fork legs. I still can't seperate these... 



I'll post some more when I've progressed a bit further...

Ta Ta

[guest27]

Hummmmmm - poor joke and possibly child unfriendly alert.




Poor joke below.....





























First pic suggests a fetish for bondage and in the second you cannot get the legs apart - is there a theme here, do you wish to discuss this amongst friends?



R

[squirrelciv]

If your struggling to undo the slider retaining bolt that threads up into the fork leg from the spindle clamp, I've found a cheap alternative to the custom tool Honda want you to buy is a wooden broom handle. Stuff it down the fork leg with a bit of gusto and hopefully it will offer enough grip to the nut end for you to undo the bolt. Best of luck.

[themoudie]

Alternatively stick the chisel end of a wrecking bar down with the fork compressed and engage with the top of the damper rod, then use a good quality 3/8 drive allen key onto the allen bolt in the base. Works on Marzzochi' every time. If really bad, try an electric impact drill or air gun to spin it off. All the best.

My regards, Bill.

[guest288]

I've managed to undo the bottom bolt up inside the fork leg, but I still can't seperate the leg from the tube... 

[guest27]

Semtex?

R

[Jez F]

Hi, is there a circlip inside the top of the leg? I struggled for ages with a KX500 rear shock until I found one hidden amongst the crud(that will teach me about not cleaning things up properly!)
Jez

[guest295]

Apparently not. The workshop manual says to slide the tube out sharply: the bushing thereon will drive the bushing and seal out of the slider.

[Jez F]

Hi, in that case put the fork leg in a vice,with something to protect the chrome, apply heat to the area around the bushing and push the slider up as far as it will go and then yank it as hard as possible, rather like a slide hammer. Had a similar problem with some Commando forks and this method worked on them.
Cheers Jez

[pigafetta]

There's no circlip but there is a sprung wire clip thing jobbie behind the dust seal.

[guest288]

I'll give it a go- I was a bit wary about how much to bash them about, but it sounds like I can give them a fair old crack. Will let you know how I get on...

[guest288]

Woohoo! 

Got the fork legs apart, ordered some seals from David Silver so should be able to get the forks finished as soon as they arrive.
Stripped the Hagon shox I got from Steve, so when the DS stuff arrives should be able to bolt in the swingarm too.
Currently cutting alloy plates too blank off the engine ports prior to getting the whole lot blasted- any particular blasting process I should ask about???

[themoudie]

Aye Dave,

Are you leaving the lump whole?

Or are you going to put castings through? By the reading you are intent on the first rather than the second. However, if you are doing the second, see this thread from the site: http://www.thumperclub.com/smf/index.php?topic=2522.0

I have to say I'd be nervous of abrasive nasties getting in the lump, if you are proposing to do it whole

My regards, Bill.

[guest288]

Hi Bill

I know that the engine was running well so I am a bit reluctant to split it, was rather hoping to put it through as a whole lump. Have heard things about soda blasting, anyone else know of this? Is there a better way of me scrubbing up the engine?? 

[themoudie]

Aye Dave,

If you are sure you can seal all the orifices I'd scrub it up with a stiff nylon washing up brush and a diesel/parrafin mix (50:50), then leave to soak. Give it another good scrubbing with more mix and leave to soak again. Now get a hold of Orange Jizer handcleanser with the polybeads in it or similar and give it a good scrubbing all over, then repeat and rinse with warm/hot water. Give it another wash with warm car shampoo and thorough rinse. Now you can Solvol what you want or just apply whatever cream/polish or else ACF50/Scotoiler365/WD40 protectant you prefer.

Regards, Bill.