Yamaha XT600 front fork rebuild

I had an XT600 come into the shop the other day with a leaking front fork seal. Now normally when a seal is leaking on one of the front forks its common practice to overhaul both forks together, replacing seals, oil & sometimes the bushes too.
This was a budget job so just the one fork got the 'Andy' treatment. The design & operation of this fork is identical to the TDR250's that I rebuilt a few weeks ago, however, some of the specs are different for the XT600 so I decided, 'What the hell', I'll make another video doing these ones....
So, if you have any questions then please just leave them below in the comments section & I'll do my very best to get back to you quickly...
Cheers
Andy Mechanic!

[@marioacunadelagarza2197]

Thanks a lot Andy for this video! I work at a repair/service/modification shop for shock absorbers in Mexico City. Your video was absolutely helpful to service an XT600 correctly.

[@AndyMechanic]

Thanks Mario, pleased it was of help. Keep up the great work. Cheers Andy

[@thodoris3790]

dude,becouse of you i saved around 60 euros...thanks for the "special tool" informations.i made one with a bolt and an iron tube,without it the job coulnt be done.i changed seals and oil.great video.thanks again

[@mtuguti]

Excellent video

[@AndyMechanic]

Thanks 😊

[@alanconway8821]

Great video, what I use as my "special tool" is an old pool cue, it has a tapered rubber bung at the handle of the cue. I just push that in, turn the fork upside down and lean on it while I go at the Allen head bolt at the bottom with a rettle gun. Seems to do the job nicely

[@AndyMechanic]

Great idea :-)

[@peterlastrucci324]

The Yamaha service manual 5vk1-AE1 specifies 640 cc oil for the 660R and 600 cc for the X, likewise 125 mm oil level without spring. I made a driver to insert the seal as I was not happy point loading it with a punch. Great tutorial though!

[@martinpeinado]

Thanks Andy, great job! Very nice and useful vid. Regards from south Spain

[@lokom18]

Thanx for the video. I will do it on my XT 3AJ :-)

[@theglumrant9477]

Great thanks! Just the help I needed

[@tomastotrenaki]

Great job! Thanks for the video, it helped a lot!

[@retromechanic7639]

my SPECIAL TOOL is a threaded rod with 2 pairs of 27mm nuts, works great

[@paulhutchison]

Great video, thanks!

[@peterwait641]

Fitted a few seals then wiggled the stanchion in afterwards with a bit of silicon lube on, easy to turn aluminium seal driver if you have access to lathe !

[@FabioBoero]

Great job Andy!!!I'll try to rebuild my forks too!! :) I hope you're gonna rebuild the whole yamaha xt 600 engine, I'd need a video tutorial for that ;) bye from Italy

[@mtuguti]

Or a tt600 34k engine

[@lemoinexavier]

thx! Have to change the seal on a XTZ660. Will be the same procedure.

[@abderrahmanehabbaaina141]

Greaaaaat, thank you so much for the deep explaining, please what it the bolt size I'll need in that handmade tool (time 14:34) for a tenere XT660Z 2013?

[@aleksandarseocanac6741]

I took off the wheel, I grabbed the right fork from the bottom and lifted it up, and the left as well! The right has a much greater load than the left! And it happens to me when I brake with the front that the engine pulls to the right! I changed the oil and oil seals 1000 km ago

[@officialmysteriousrider6327]

I bet it had a aftermark one in otherside mate just was looking at fork tube extension's made cnc never new you could get them for the forks i new you could get jackup links for the shock relay but didn't like the idea of my dt125r looking like it was going down a hill stood up. what thread size is the fork tube caps on the top the one's you took of with the windy gun should be same as dt the xt as they share odd parts

[@DavidRoberts5]

Great Video Andy. Are the 2003 TT 600R models the same as the XT in your video?

[@tomocef7488]

Andy mechanic What screw ( tool) there in video is 24 for Yamaha 600 )I can use to rebuild Yamaha xtx 660 2007 forks ?

[@PedroPedro-jm4lk]

Ah man.. Thank you for this video. I have just purchased my used 2015 YamTenere 660. Awesome bike but boy do those front shocks need firming up! Thanks for your video, I now know I can tackle the job. Also, do I hear some Yorkshire Tones in your fused accent?

[@AndyMechanic]

Hey, no problem, pleased you found the video helpful. Yes, a true Yorkshire man though my accent has mellowed significantly since moving to New Zealand! Good luck with the rebuild. Cheers Andy

[@mohhingman]

The nut for the special tool is 27mm not 22mm

[@TheBrainHacker888]

your video are thge best. hope you can sell some tool hand made, let me know

[@stefanopozzarini5891]

Do you know what brand are a 1984 43f front fork? Showa Or kajaba?

[@larscajvall5804]

I have a TT600 RE, 2004. Is it the same procedur? THX for a good video.

[@AndyMechanic]

Likely similar processes but I haven't done one of those. I'd definitely check the manual too... Cheers Andy

[@noobonpc275]

how do i find out what tools i need for a xr650r? nice vid by the way, thank you!

[@AndyMechanic]

+Nick Platt extremely difficult as the workshop manual only lists Honda special tool numbers rather than dimensions. I'd suggest maybe downloading a Haynes manual as they may tell you more about the tools needed. Otherwise just start the strip down and use a torch to look down inside to see then make something up. Sometimes you can strip down with only a windy gun (air tools) but need the special tool to hold the cartridge in place whilst you torque up the lower retaining Bolt. .. Hope that's helped a little. Cheers Andy

[@icsmister714]

@Andy Mechanic, I have a Yamaha XT 600 E 3TB 1992, do you know what is the exact quantity of oil I have to pour inside each fork tube? ☺

[@thinkbig24]

538ml

[@icsmister714]

@@thinkbig24 Thank you!!!

[@araujobeto]

show de bola

[@bigcat3175]

I don't have anything inside hold on to please halp

[@b3rboy905]

can i change the oil seal without removing the extencion fork?

[@AndyMechanic]

+giuliano calagiu ? Lol

[@AndyMechanic]

+giuliano calagiu Nop. Not really. I have done it but it's very difficult and you risk damaging the chrome surface.

[@b3rboy905]

Andy Mechanic thank you

[@depressedcoon]

Assembly is wrong. You forgot in insert the oil lock piece before tightening the bottom bolt.

[@danishalirana]

What are seal sizes? Both front forks?

[@AndyMechanic]

+Danish Rana Sorry Danish, I really have no idea as I used genuine seals. Sorry. You should be able to go on line and find an aftermarket supplier that will know the size. But remember...genuine is best :-)

[@danishalirana]

Andy Mechanic yes.. ill go for the genuine ones. If i can.. cuz i dont find the genuine in my country so easily 😁

[@danishalirana]

Thanks :)

[@johnchaser1892]

I suppose you already got them, but maybe someone will use the infos: For a 43F: dust seal: 41x53.7x9.5, oil seal: 41x53x10.5, upper bushing 41x45x12 with teflon on the inside, lower bushing 40x42x20 with teflon on the outside. I dont know but think that these sizes apply to later models as well. Hope this helps someone out. Cheers!