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My E-Series service manual does not have any info regarding the USD forks. Right now I'm pretty sure it's seriously low as the forks do not have much compression/rebound.

How do I check the fork fluid level, and refill the fork? I'm just looking to add fluid to get me by and refill as necessary until I can afford a proper rebuild with a stiffer rate spring. Can I just loosen the top of the triple tree, unscrew the caps, add fluid, and compress/decompress the forks to bleed?

This link on our very own site: USD Servicing remove the fork legs from the bike and then do steps 1-3 to remove the spring, then skip to step 39 to refill and bleed. Don't have my E manual addendum in front of me but it seems like 100 - 120 mm from the top of the compressed fork tubes is the normal range for oil height. If you're going to refill the fork just drain all the old oil out and replace it. Usually takes just over a quart to do both legs so you end up having to buy 2 bottles of oil (pretty sure they did that on purpose )

Per my service manual:
Oil viscosity: Kayaba 01 or SAE 5W
Oil Capacity: 471 +/- 4 ml.
Oil level (fully compressed, spring removed): 80 +/- 2mm (from top of outer tube)

I "think" it is 80 mm - 100 mm on the 1993 - 1994 KDX200's.

You will need to take the springs out to get an accurate reading.

By the way, one liter DOES work for both 1993 - 1994 KDX200 fork tubes. As they have 41 mm inner tubes, they do not hold as much oil as the 43 mm tubes, for example.

EDIT: sarrant beat me to it while I was typing.

Jason wrote:By the way, one liter DOES work for both 1993 - 1994 KDX200 fork tubes. As they have 41 mm inner tubes, they do not hold as much oil as the 43 mm tubes, for example.

Makes sense, my 2001 KX250 forks are a bit bigger than my dad's 93 USDs. But the fork oil comes in 1 quart bottles (.94 liters which is exactly the volume of both tubes (471 ml X 2)) and I always end up just a little short. If I could get it in liter bottles that would fix everything!

Problem solved:

Any thoughts on using ATF instead of fork oil? Will the added viscosity hurt anything, or just bump up the compression/rebound range of adjustment. I'm roughly 240lbs with gear, and the forks are bottoming out pretty regularly. I ride anything from tight woods to open red clay with a few small drops (2'-4').

I've used ATF before on them, and it felt ok, but your problem is that you need heavier springs, not heavier oil.

At 240 you are badly undersprung on the stock forks, they are good for someone around 100 pounds lighter. Your rear end is going to need to be resprung as well. An oil change isn't going to buy you anything until the bike is sprung properly.

Oh, and I should have said if I can get it in 1 liter bottles that doesn't cost an arm and a leg lol. I usually use KYB but not the Kawi OEM version.

Yep, different springs are needed?

How long have you had the bike?

How long since the lat fork / shock oil changes, suspension rebuild, if ever?

I bought the bike basically in running, but not driving condition in March. Took the case apart to find 5th gear was seized on the input shaft, rebuilt the engine, and realized proper size jets were not available for the carb on it. Bought a PWK35, took it out for a shakedown to find that the swingarm bushings/bearings were toast. This week I threw on a used swingarm with good bearings/bushings, the linkage seemed fine, but wanted to do a half step with the forks until I can do a proper rebuild on them.

The forks right now are pretty much spring only without any damping. I was just thinking of running a thicker oil to prevent bottoming out the forks even if it's going to be rough on roots/rocks. I won't be doing any racing soon, but this weekend I'll be riding with a couple modded pitbikes and then meeting up a couple DRZ's on street tires.

ATF will get you going. Congratulations on getting it going.

They're valved/sprung so soft, that even with a heavier oil, I don't think you'll find them harsh at all over the small stuff.

Thanks! It's been great to get back onto 2 wheels of my own. I've been riding borrowed bikes when I could, but when this bike popped up within my budget I had to pick it up... even knowing it'd Nickel and Dime me.

So how much did it set you back?

I have around $600 in it total at this point. I'm still not upside down, but getting closer to sorted bike pricing for an E model around here.

So, you are just trying to flip it or what?

Nope, I've been wanting a dirtbike for quite a while. I just needed a low buy-in. I'm hoping to get my wife riding, and eventually pick up another bike as well. I was just saying that I'm happy that Ive been able to get it going for less than buying something ready to go.

Enjoy it while it lasts. Dirt bikes are a money pit.

Yeah, I'm just trying to do it with a shoestring budget. Seems like most of my hobbies tend to get expensive quick. So far my autocross/HDPE car has won the battle for money pit though.