How to Rebuild Dirtbike Forks - Honda XR 200 Seal Replacement & Mods

This is a step by step tutorial on rebuilding conventional dirtbike forks off of a Honda XR 200. I walk you through how to take them apart, replace the seals, and re-assemble the forks, as well as a couple of cheap mods you can do to stiffen them up.
3:05 - How to remove Allen bolt without special Honda Tools
5:20 - How to separate Inner and Outer Fork Tubes
11:20 - Installing New Seals
14:20 - Fork Mods to Stiffen Forks
20:00 - Filling Forks with Oil
Fork Seal Kit Used: amzn.to/2ldFiBx
15 Wt Fork Oil: amzn.to/2lPhq7n
For day to day stuff:
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[@chrispageXR200r]

The torque spec in my manual is 15 to 18 foot pounds. Great job in the video. Thank you.

[@sigourneywhaynedavid4650]

the most detailed fork servicing i ever saw. love the video. keep it up man.

[@MotoFlightGuy]

Thank you!

[@beachthor1]

Just picked up this exact bike, novice trail rider myself. So psyched on how easy and cheap it is to work on these, thanks so much for the vids!

[@scottmilton6766]

Great Job I have a 1997 XR200I bought in an estimate sale along with XR80. The forks on the 200 are leaking oil and I had to change out the rear mono shock. But great job on the video. Thank you so much I am an older rider like your dad and the forks are weak.

[@riclopez1627]

You can also reinstall the fork spring and cap to apply pressure to remove the lower assembly bolt. Good video. 👍🏽

[@blackguns12]

This will really help me rebuild my forks. Thanks man! Keep it up. Very detailed instructions

[@jangarcia3466]

Man this is the most detailed rebuild I’ve ever watched. Keep posting my friend. You help a lot of people. 🙏🏽

[@MotoFlightGuy]

Thank you! I appreciate the kind words. I've been lacking on videos lately. I need to get back to it

[@Thoughtmanifestkingdom]

@@MotoFlightGuy Very good video, if you have been lacking you should not, you are very good at it, the explanations, the shortcuts without the correct tools, the easy step by step instruction, i could watch you rebuild anything and it would be interesting. Thanks very much for the video it is and will be a great help for me and many others 🙏👍😎🍌🍌🍌🍌

[@MotoFlightGuy]

@@Thoughtmanifestkingdom Thanks for the kind words!!!

[@harambestilllives3101]

I like the ideas you have reassembling with out the expensive tools. Everyday items use to rebuild! Thank you for your ideas, and it is an awesome video!

[@MotoFlightGuy]

Thanks for the comments! Yeah I usually hate buying specialty tools if I don't have to

[@gggg-mt1he]

Picking up a xr 200r tomorrow for my girlfriend ls birthday glad there is a large community around them

[@aussiefarmer8741]

The "special fork tool" can be made easily, Its usually a 27mm approx hex nut/bolt welded to a bit of tube. It doesn't matter that the spline inside is multi pointed its just like a socket, the std hex head will fit in, it doesn't need to fit all the splines. Very simple to make. Good vid.

[@619Rider69]

Yep!👍👍👍

[@skookum696]

Super helpful!!! More XR vids please!

[@christopheryeagley2467]

Explained it well enough for me to feel like I can do it

[@MotoFlightGuy]

Thanks. Yeah it really is a simple set of forks. Not much to go wrong honestly

[@paulwatson2499]

Great video thanks for posting.. gave me some good ideas for when i rebuild my 1979 XR250 Flintstone forks...

[@douglynch8791]

Thanks. Helped a lot. Did my YZ forks after watching.

[@tommac215]

Awesome video mate thanks for your help

[@EduardoFerreira-ni9qm]

GREAT tutorial. I do have two XR200R, and both need front suspension work. This will help me a lot. Thanks

[@MotoFlightGuy]

No problem 👍

[@jasongiles1038]

I just recently bought an 82 XR 200r for $350 cranks and runs. I heard they were the legends of the 80's. Can't wait to finish my restro on it!

[@dougatdesertdemongarage7777]

Very good job young man

[@komododragon4242]

Dude, great video. Thanks man.

[@MotoFlightGuy]

Glad you liked it!

[@bennarloch6813]

This was very helpful thank you

[@joshuacampbell9990]

As one who paid to have forks done back when I rode bikes constantly, I now feel like I should have learned the tricks myself.

[@mattl1330]

This is a great tutorial. I am bringing my XR200 back to life and you have provided awesome tips. Would you consider making a how to video on servicing the rear shock of this XR200? Thank you.

[@MotoFlightGuy]

I wish I could find a shock upgrade. I haven't been into the shock yet. Not sure if it's worth it or not. Love these old bikes though!

[@bigwaggo]

Perfect. Thank you so much.

[@ryu1014]

Thanks aLot , I hope there are more videos on the xR200 bike. Maintenance and more.

[@julianmorris9951]

Just stripped the forks today on a 1981 rm465 I’m restoring and their almost exactly the same as these, I’d got the jist of things but some great tips in your vid like the plastic trick for the seals 😄 👍🇬🇧🇺🇸

[@MotoFlightGuy]

Oh that's a vintage beast! Yeah I figure most of the standard forks are similar even though I haven't been into that many sets. Much easier than USD forks

[@fritzschippert8420]

Hah mine is a 82 it 465

[@julianmorris9951]

@@fritzschippert8420 probably got the same forks as the rm🤔

[@MotoFlightGuy]

@@fritzschippert8420 I've always wanted to ride one of the old big bore 2 stroke bikes. I've heard the hype lol

[@mikeburton5482]

You can also sometimes break your bottom ( dampening rod) bolt loose before you take the spring and cap off. Going back is the same, just get it as tight as you can before it goes together. Watch out for oil leak .

[@guiltfreeape]

I also tried this and it worked.

[@Duppavich]

That's what I'm going to try, I think that will work 👍

[@619Rider69]

😂😂 glad you said it… we are on the same page I have rebuilt hundreds of these forks and you are absolutely right. I would be surprised if they didn’t leak oil.

[@chrispageXR200r]

Also noted from my 1983 has a taper at one end of the main spring, and that goes downward.

[@Jrixi]

Great video

[@MotoFlightGuy]

Thanks!

[@elizabethtruman7164]

Hey that's very helpful ,I can't find a video on the Honda TLR 200 reflex I'm guessing it's very similar Pleas advise kind regards Bell

[@icanseeyouallfromuphere]

Same forks on my 1983 XR200R 👍🏻

[@markprater72]

Your tutorial is fantastic. Thank you. I followed you step for step on my xr 200r but for some reason there is no steel spacer in my forks. What is the overall length of your modified spacer?

[@MotoFlightGuy]

Hmm, is it possible you have aftermarket springs? I don't remember the length exactly

[@thehungryhunter3454]

excellent video man you really know your stuff but what about the air did you put air in the forks afterwords if so how much Thanks!

[@MotoFlightGuy]

Yes I put air in there. I'm forgetting the pressure limit off the top of my head. I wanna say we put 10psi in each fork

[@brianwehling555]

Thanks for the detailed video. Any idea if I can follow the same instructions for a 1996 XR250R?

[@tysonturnervlogs13]

I think you can

[@jocelawit2414]

Sir me i know again how much mL the fork oil? Thank you for your answer god bless you very detailed

[@PeterrrMan]

Where did you get the red fork gators? Or a link if you have them, thanks!

[@robinhall3725]

Yea I used a weed eater tube instead of pvc.. worked great. Thanx man. Now what to do w rear shock?

[@MotoFlightGuy]

Thats a good question lol. I haven't found an easy solution for the rear shock. If you do, let me know!

[@jhejhobbies5850]

Great video, thanks for the helpful tips. I have an xr200 myself that desperately needs a stiffer front end. How did those mods work for you? Would you recommend the same mods, extended spring compressor and 15wt fork oil for a 200 lb. Rider? Also what psi did you put in those forks with the mods?

[@MotoFlightGuy]

100% would recommend copying this. I haven't got to play with air pressures yet. Think we started with 10psi if I recall. I wanna do more testing since there's some interest in the fork mod and see what air pressure does to the ride

[@jhejhobbies5850]

@@MotoFlightGuy thanks for the reply. I would love to see a more detailed review/ ride video of the completed process. When I got mine the rear shock was shot so I got an XL250 shock for cheap, it works but it added quite a bit of height, so that combined with the really soft forks that are well past due for a service anyways has made for not a great ride.

[@ianbozovich2242]

How much air pressure do you use once it’s all back together?

[@TheBoBabsin]

This is awesome and very informative. Do you know whether or not the earlier (81-83) XR200Rs have the same forks, or would the process differ slightly for those? Also, how much air should I put in via the Schrader valve?

[@MotoFlightGuy]

It should be very similar. Close enough to get it done. I can't remember how much air is recommended. It's difficult to find that information but I know we didn't go over 10 psi

[@kennethlourisombrog2149]

nice

[@davidandrew3481]

Please do the XR250R rear shock Rebuild

[@lukehaycock4856]

Great video, do you know if this would be the correct method for a 95 cr80r?

[@MotoFlightGuy]

I don't know but if they are conventional forks its probably similar

[@Junior-fd8ux]

@@MotoFlightGuy i found this video for doing 89 cr125 conventional forks an its pretty much the same. Best to have a manuel also to know forsure

[@stubabyfuora5280]

Well, good video, but remove springs to add oil, 15w oil is overkill and fork will skip wheel over roots and rocks, I prefer m10 metric washers as you can quickly adjust your preload that way. I always convert to earlier 10” travel forks and rebuildable shock for a truly fun fast 200. Getting 8” stock stuff to handle above walking speeds is just not worth the effort

[@haythamsamer9219]

Please how many liters u but in … thanks 🙏

[@davidandrew3481]

Is this similar to the XR250R?!!

[@AllenSpeck]

Did the 1.25" preload work or was it too much?

[@MotoFlightGuy]

Definitely not. The forks worked out fantastic

[@vwbuge1]

I have a 98 and oddly my forks DO NOT have the drain screw at the bottom.

[@jasongiles1038]

Nice job! Maybe next video remove the hat. The bill gets in the way of the work. Lol

[@leonardmabascog2673]

Hello po how many milliliters or ml fork oil added in one side of suspension.for xr200 fork

[@EduardoFerreira-ni9qm]

378.5ml

[@seb42]

What direction does the oil seal go in?

[@MotoFlightGuy]

The side with the wiper goes on the top side

[@devincumming231]

What did you use for gas in the tubes

[@MotoFlightGuy]

Just shop air

[@russ4454]

I have a 94 xr200r

[@howardbritten1186]

Applying preload to a spring does NOT change its spring rate. It does NOT become stiffer It simply makes the bike ride a bit higher. If you want to increase the 'effective' spring rate, you can do so by increasing the oil level within the fork. When the fork compresses, the air inside it compresses and provides an air spring. With more oil in the fork, you increase the compression ratio of the air that's in there. By adding air pressure as well, the effect of the air spring as the fork compresses is even greater. Some people remove the steel spring altogether and run about 50psi of air pressure as the only spring, however, this tends to give an effective spring rate that is too high to ride comfortably. With the progressive linkage (Pro-Link) rear suspension on the XRs, if you increase preload on the spring of the rear shocker, you will actually make the rear end softer!

[@janeblogs324]

What did the seal kit cost?

[@nathangregory9002]

It's like $30

[@63oddball]

Do you not need to refill air ?

[@MotoFlightGuy]

Yeah, you need to put air back in. You can look up the specs for air, do not quote me but I think you can do something like up to like 10 lbs of air maybe?

[@mariomessinese5287]

That's called a dampening rod the one with the bolt that goes through the bottom.

[@wwearmandoma]

What should the air pressure be?

[@MotoFlightGuy]

I believe they can run up to 10psi but I honestly can't remember. I researched it at the time and I believe we put around 5-7psi in these forks. The air pressure can be used as a tuning method

[@janeblogs324]

Nitrogen is best but hard to diy

[@williamsherman1089]

So what are the results of the mod, was it a good improvement? I'm looking to get one of these bikes, always wanted one but I'm a bit weightier now that I'm older and I know I will have to beef up suspension. I know I could go up to a 250 but I love the size and weight of the 200. Your verdict on this mod would be greatly appreciated.

[@MotoFlightGuy]

I guess it depends on your weight. I have ridden the bike a bit, and the forks feel great for me, but I'm 150 and ride the bike aggressive. My dad is somewhere in the 180-190 range if I remember correctly. He says the forks feel perfect to him, but he's also riding at a slower pace. If you are 200lbs or under, and you aren't trying to push the bike to a racing pace through the woods, I'd recommend it. Over 200lbs and I would say this just isn't enough bike, regardless of mods.

[@williamsherman1089]

@@MotoFlightGuy Hey thanks for replying back bud, good info your tutorial was great.

[@csedan510]

What about the air?

[@mcmactoaster27]

Will this work for a 2001?

[@MotoFlightGuy]

Ummm it should. I think the forks are the same. If not they are very very similar

[@razolgandal5837]

Can i convert from oz to mL?

[@fanistsitsikaos7378]

???????????

[@EduardoFerreira-ni9qm]

@@fanistsitsikaos7378 378.5ml

[@its_me_ruff2474]

I'll be the first comment cause I own one

[@MotoFlightGuy]

Solid bike, even though I have been riding full race bikes for the last 15 years, I thought the XR was more than capable

[@jamesholbrook3648]

During the overhead shots the bill of your hat blocks your work area, just fyi

[@MotoFlightGuy]

Yeah I didn't realize this until the end. Unfortunately didn't want to re shoot it all lol

[@ohv199]

The "inner rod" is called a damper rod

[@bigfish74f]

If your gonna hammer that seal put the old one on top first

[@MotoFlightGuy]

That would take away a lot of energy being used to drive the seal in. The point of the seal driver, be it homemade or something you buy, is to spread out the force, which is safe for the seal.