First off, I had the incorrect forks for my 1980 XT500 G. They were from an earlier model that had the axle mounted ‘inline’ on the underside of the of the legs (1976-1979). They were also a different length, the earlier type should protrude above the top clamp by 35mm to 55mm. There is not enough space to do this on later models. The 1980 and later had leading axles, i.e. mounted to the front of the leg. The triple clamps were correct being ‘straight’ rather than ‘v’ shaped as for the earlier models. Having these mixed up didn’t hurt but I’ll probably notice improved handling once I have the correct combo.
Even if they had been the correct version, I’d have had to buy new stanchions or had them re-chromed as the corrosion was really bad at the top. The cost of which is comparable to getting a used pair.
So I immediately started looking for a secondhand pair. I was looking for rust free if possible. Within a week I found a pair on Subito.it for sale in Milan. They were off an Italian 1980 XT500 so the bottom of the legs were black. There are spots of rust at the top but well away from the area of travel. As the Australian 1980 version has unpainted legs I had to remove the black paint then polish the aluminium. I used a clear lacquer to finish but this has dulled the shine somewhat. I haven’t dismantled them, preferring to try them out first, change the oil, and then, if necessary, refurbish them at that time.
The gators (boots) were still useable, no holes or splits, but as they were old they had hardened some. To get the bottom to fit over the shoulder I first warmed them in hot water (not boiling!) to make them a little more pliable. Fastened them with cable zip ties.
