Changing Fork Springs (XT600E)

[Edgar]

Changing Fork Springs XT600E DJ02

I'm helping a friend to do an overhaul (or more or less general) on your machine ...

One of the things we decided to do was change the front suspension springs ...

When taking old and new ... is easy ...

but the truth is that things are not as linear as it

The springs we buy are fatter and longer than the original ...


So if this is not to be possible by the same amount of oil
which brought factory
because the logical volume of the spring is gradually increased and when we use the whole course of the suspension let's retainers in an effort


Can anyone give me an opinion on this issue?

[Edgar]

While I wait for the tip
I posted something in the process ...


The machine in the intensive care area of the garage is a XT600E DJ02 (2003)

I bought a stand of Montejunto (red wine) and put the dame in a position to take away the suspension

before taking the cuffs unscrew the plug with a wrench 22mm
because it is easier to do while the site is still fixed






I removed the oil into an empty container in order to measure the amount of oil that took
and left little more than 0.5 L
supposed to leave 0.533 L


I measured the spring source to make a record ...
He hit it right with what is in the manual


But I found a piece unless the fork

the manual comes with a washer on the end of the spring (No. 4)
and another washer (No. 2) at the end of the spacer (3)

What I found was a washer between the spacer and the spring ... and nothing else ...

But if you do not come is because it does not require ... and the less weight rather





A photo of a spacer ...

[Edgar]

The process of changing the oil is very simple and easy


Translation of the image:
capacity of each suspension is 533cm3
Oil recommended is 10W
after completing with the oil, should collect the suspension several times to distribute oil
The oil level is 145mm to the top
with the inner tube fully compressed without spring




But in this case let's change the springs

and new springs are bigger and fatter

will occupy more space than the original ... much more volume ...

Springs source: 475 mm / 34.8 mm / 4.8 mm
Progressive springs: 635 mm / 34.7 mm / 5.25 mm

the spacer that comes standard with 14 cm will have to leave

and this space is a simple tube with a 1mm wall and will be replaced by fat spring


WILL I HAVE TO OIL FOR LESS?

ANYONE CAN HELP ME RESPONDING TO IT?

[socks]

The process of changing the oil is very simple and easy


Translation of the image:
capacity of each suspension is 533cm3
Oil recommended is 10W
after completing with the oil, should collect the suspension several times to distribute oil
The oil level is 145mm to the top
with the inner tube fully compressed without spring




But in this case let's change the springs

and new springs are bigger and fatter

will occupy more space than the original ... much more volume ...

Springs source: 475 mm / 34.8 mm / 4.8 mm
Progressive springs: 635 mm / 34.7 mm / 5.25 mm

the spacer that comes standard with 14 cm will have to leave

and this space is a simple tube with a 1mm wall and will be replaced by fat spring


WILL I HAVE TO OIL FOR LESS?

ANYONE CAN HELP ME RESPONDING TO IT?

Yo Edgar

I can not be 100% sure. but you appear to be doing the correct way.

Can you inform us who is making the new spring and if it is a "proggresive spring" that is can you see and describe the spring, like is it tighter coil to the top of the spring more information required!

It looks like you get rid of the washer spacer from the measurements you have provided and that you should keep the spacer that is more than a washer (4) for the top of the spring, if it fits.

I would hope that others here on the forum will chirp in soon. Infact Vandor is in your neck of the woods (in Portugal I believe) and he has done a fair bit on fork changing (if that correct Vandor) and thus has a fair knowledge therefore may be able to help guide you on this.

Normally the seller of the new spring would inform the buyer how much oil should be replaced. If they know! this is why I ask for more information on the new spring. Whats it say on the box it came in? Name and numbers?

As I say some one will be along soon with a more comprehensive reply.
In the mean time go and have a beer or two then sit back and take all in that you can see.

best of luck on this and let us know how it works out.

Socks

[ActionManMelb]

the manual comes with a washer on the end of the spring (No. 4)
and another washer (No. 2) at the end of the spacer (3)

Don't worry, item No. 2 is the o'ring seal for the large top nut.

The oil level is critical for only one reason. So that you never completely fill the tube and have a "hydraulic lock situation" which will force out the oil seals.

Step 1 : This will be MESSY, but fill the tube to the 145mm level and then immerse the OLD spring and measure the oil level. (80mm??)
Step 2 : Now remove the OLD spring, reset the level to 145mm (oil loss, drips etc.).
step 3 : Now immerse the NEW spring and check the oil level. It will be higher.(50mm??)
Step 4 : Now remove oil to obtain the same level as in step 1.

Note how much oil you have to remove and write in the service manual and post here so we can all learn.

[Edgar]

@ socks

@ActionManMelb



thank you
the fast and insightful response

I lack a response from the seller of the springs

and so I have more news, I write here ...

anyway, after determining that the new measure of oil

I'll post the number of springs
as well as the place of purchase
(just not done yet because it was not me who bought it)
and the oil that got into and what quantities ...

[Edgar]

everything is already in place and functioning


There was the doubt what would be the amount of oil to use with the new springs ...

since the new springs had more volume than the old ... we would do differently the manual from Yamaha ...

but the reality was not quite so ... and after some questions and seeking answers to these questions ... the solution appeared ...


That is ...
will always be air in the suspension even at the end of your course ... (and this "air" will be more or less compressed)

For example:
to have a setting we put 533cl
and if put 500cl have another setting
but will work with both because it will be divided by a buffer "spring" "oil" and "air"
(lastly the "air" is compressed and does the same job that the gas in the rear bumper)

The manufacturer says to spring for a 10W oil with 538cl
http://www.wirth-federn.de/products/de/ ... 2-96-.html
and should have a height of 160mm from the top without spring fully withdrawn with the sheath ...


Another important
The service manual of XT600E there translated into Portuguese, a Brazilian and has some different values ​​of the German manual ...
do not ask me why!

The German says that the suspension takes on each side 538cl
and the Brazilian 533cl
the height of the air cushion is 155mm in Germany
and 145mm in Brazil



makes no sense and do not understand why these values

to create more confusion and measured the amount of oil that was set and it was not one thing nor the other
was 170mm
I was even more confused ...


and then got a cushion of 160mm


1 - fork
2 - screw cap with oring
3 - ring that goes between the spacer and the spring
4 - original spring
5 - spacer
6 - new spring (progressive)
7 - vacuum intelligent oil
8 - 10W oil suspension






One more picture of the vacuum oil, home made




The assembly process is simple and easy


Translation of the image:
capacity of each suspension is 533cm3
Oil recommended is 10W
after completing with the oil, should collect the suspension several times to distribute oil
The oil level is 145mm to the top
with the inner tube fully compressed without spring


The XT was higher 15 mm in front




The oil that came out was burgundy ... more like a wine roze

[Mezo]

Sounds like they was using power steering fluid (rose).

Thanks for sharing Edgar.

Mezo.

[ActionManMelb]

The service manual of XT600E there translated into Portuguese, a Brazilian and has some different values ​​of the German manual ...

The German says that the suspension takes on each side 538cl and the Brazilian 533cl
the height of the air cushion is 155mm in Germany and 145mm in Brazil
makes no sense and do not understand why these values

The ever thoughtful engineers at Yamaha have given a different specification according to the road conditions they would expect the proud
owner to find in his own country.

The larger the air cushion, the softer and plusher the suspension feel.
Autobahn in Germany, cow trail in Brazil!!