Originally Posted by redprimo
I picked up a basket case 83XR500R and was going to use the front end on my 80XL500s. The stem is about an inch longer on the 83XR500R which is a solvable problem, but what has me stymied now is that the forks on the 83XL500R are 6" longer than what is on my 80XL500s.
I have never rebuilt forks on anything other than a CT 90 so I have no idea of what real forks look like. Can they be cut down? from the illustrated parts list it looks like all I would have to do is cut the springs and the tubes and probably re-thread the top of the tube, is there more to it than this?
If you only cut the spring it will shorten to ride higth. Now the problem with that is if the forks extend past that you will be in free travle. (Unsprung) the xr400 forks where the same lingth as my 82 xl500rs forks. But they road higher in the travle so I had to lower the tripples almost an inch and rase the sag to get her level again. But if you are going frol a 23 inch front on the 80 modle to a 21 inch tire you will be loseing a few inched there. Also you don't know how high they will ride when the bikes weight is on it. All you can do is misure ground to handle bars with stock forks then do the same with the newer forksif is taller just ajust the bike to make it sit level again.