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


For day to day stuff:

Gear that I use to make these videos:

[sigourneywhaynedavid]

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

[chrispageXRr]

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

[scottmilton]

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.

[riclopez]

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

[blackguns]

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

[jangarcia]

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

[harambestilllives]

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!

[aussiefarmer]

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.

[gggg-mthe]

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

[christopheryeagley]

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

[EduardoFerreira-niqm]

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

[paulwatson]

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

[mikeburton]

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 .

[julianmorris]

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 😄 👍🇬🇧🇺🇸

[douglynch]

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

[mattl]

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.

[ianbozovich]

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

[tommac]

Awesome video mate thanks for your help

[ryu]

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

[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?