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Old 03-18-2015, 10:46 AM   #1
DogBunny OP
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Joined: Nov 2014
Location: Austin, TX
Oddometer: 16
XS650 steering stem onto XT500 or TT500 front end swap

How to remove the XT500 or TT500 steering stem and swap it into an XS650 triple tree so that the XS650 front end can be used on the XT/TT500. This is a popular mod when converting the XT/TT500 to a street bike. I am using a 1978 XT500 steering stem on a 1977 or later XS650 35mm front end in the pics.

STEP ONE:
http://www.xs650.com/forum/showthread.php?t=30169
Read the above thread by XS650.com Forum member PonyRide. It is excellent, and is how I figured out how to do my swap. Thank you PonyRide!
This thread will only focus on the differences.

I suggest that you take a lot of pictures and measurements of how both the XS650 and the XT/TT500 stem sits in its tree before and during doing any disassembly from the frame if possible.

I removed the XS650 stem from the bottom yoke exactly as PonyRide describes. I used a tungstem carbide ball burr under running water to keep the cut cool. As PonyRide describes, you have to cut deeper than you think.
Removing the XT/TT500 stem from its bottom yoke is easy. The XT/TT500 stem is not welded to the yoke, it is just held on with a pinch bolt. Remove the bolt, and the stem will press right out.


XT/TT500 and XS650 stems after pressing out from their bottom yokes. The XT/TT500 stem has a collar welded onto it that has to be removed.


XT/TT500 stem after collar ground off.


XT/TT500 stem pressed onto the XS650 bottom yoke. This is why I said to take pictures and measurements. It is hard to know just how far to press the stem in before you have installed your new tapered neck bearings. Fortunately, there is a fair amount of leeway.


Welded stem.


1978 Yamaha XT500 with 35 mm XS650 front end.


Before picture of the XT500.
More pics of the bike are here: http://www.advrider.com/forums/showt...php?p=26386383

DogBunny screwed with this post 03-18-2015 at 10:58 AM
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Old 03-19-2015, 06:03 AM   #2
Motomochila
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Great looking bike, but I gotta ask; why put an old front end that doesn't work worth a damn on that bike? Ceriani forks work three times better and still give you the "vintage" look. You can also swap for a set of NOS redwing forks for less than $300 and now you have adjustable vintage racing forks.
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Old 03-19-2015, 06:41 AM   #3
DogBunny OP
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Quote:
Originally Posted by Motomochila View Post
Great looking bike, but I gotta ask; why put an old front end that doesn't work worth a damn on that bike? Ceriani forks work three times better and still give you the "vintage" look. You can also swap for a set of NOS redwing forks for less than $300 and now you have adjustable vintage racing forks.
Where were you 3 months ago when I began? I will definitely look into your recommendations for next time.
However, I am an XS650 guy, I have many, I mean many XS650s, so the whole front end, forks, triples, wheel, caliper, was readily available. Also, there is a modification called the Minton Mod for XS650 forks that I did that improves them considerbly, but yeah, that just makes them "okay."
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Old 03-19-2015, 07:41 AM   #4
Motomochila
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Me too on the XS. I'm in the process of building a street tracker now, but the SR 500 is on my build list. Here's my bike now. Track master frame with KTM Super Duke inverted forks. It's almost done but I don't have pics loaded in Smugmug to link.


Here's something to wet your appetite
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Old 03-19-2015, 08:47 AM   #5
DogBunny OP
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You are a real builder. Not sure what I like more, your bike or the bender.
Never heard of Track Master, I had to look it up. I like the swingarm you made.

Very nice 500, I assume that's a Japanese builder.
http://www.xs650.com/forum/showthread.php?t=40074
Here's something to whet your appetite. I was financially challenged when it was available, but I'm now kicking myself -- I should have gone even further into debt to buy it. That engine is worth $4000 easy, and the 70-71 XS650 front wheel built like that is worth at least $700...
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