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Got everything together and tackled the tubes and seals tonight. It's really very easy other than cracking the thread lock seal on the bottom.

I drove the seals in by putting one of the old ones over top of the new one and working them down with a large screw driver and a hammer...

Here is a look at the tool. The nut that fits into the damper rod holder is 29mm.








In no particular order, here is the entire contents of a single fork leg



Et voila, new seals and no more leaks. Just waiting on a pair of shock sox and I can go riding. Cheers!

Great job on the tool.

Congratulations on getting it all going.

Helps to have a brother in instrumentation...the full suspension tune-up will make a huge different this summer

Thread revival..

Bufftester, regarding preload spacers you mention on page 3 for stiffening up the springs.

You said PVC, well my brother made some out of steel where he works by basically milling a tube out a solid piece of steel bar. Just wondering what length of preload felt just about right? The stock preload spacer is 11cm so I asked him to make a pair at 14cm to start with. After that if the suspension feels to stiff I can have him shave off a cm or two

Yeah, we used PVC because its cheap and easy to cut, but any spacer material will work. You might have him machine it at like 11mm and then machine up some 1 or 2mm washers for fine tuning. IIRC I used about 14mm to get the right sage, but that was back before I built my hybrid so it's all a little foggy

Thanks for the reply so I'm probably way off with going up 3 whole cm. No worries, I can just trim off a couple cm/mm for fine tuning. He also made them a bit thicker steel so they line up and match the cup on the underside of the cap. If yours were H conventionals, they are built a little differently with a rod through retaining the washer, spacer and top cap

4mm is what Race Tech is recommending now.

These are E conventional forks though, remember they're super soft. Where does racetech recommend 4mm. Is that somewhere on their website?

Edit: found it here
http://racetech.com/ProductSearch/1/Kaw ... DX200/1990

Yes. They are super soft. That is why you bought the correct rate springs for your weight, correct? Correct? We are not having a conversation about incorrect spring rates, correct? Correct?

If I had another $150 to blow on my kdx this summer I might consider it! But I think I already pretty much hit my budget cap with tires, chain, bars, piston etc ...

The idea by adding extra preload to the spring will boost the rebound a little bit

You're gonna have to buy springs for it, it is what it is....Do OEM H series springs fit in those forks?

$150?? Keep an eye on eBay or post a WANTED ad on this site.

OEM 1995+ KDX springs do fit the 1986 - 1992 forks.

For the record, they DO NOT fit 1993 - 1994 KDX200 USD forks.

Stock Fork Spring Rate: 0.298 kg/mm(stock)
...
Recommended Fork Spring Rate: 0.422 kg/mm (use closest available)

=

RT FRK SPR 36.8x472 .46kg

EIBACH FORK SPRINGS .45kg

Both of which are $120US + shipping. At least now I know what to look for in terms of spring rate

Gotanubike wrote:Stock Fork Spring Rate: 0.298 kg/mm(stock)
...
Recommended Fork Spring Rate: 0.422 kg/mm (use closest available)

=

RT FRK SPR 36.8x472 .46kg

EIBACH FORK SPRINGS .45kg

Both of which are $120US + shipping. At least now I know what to look for in terms of spring rate

A set of stock H springs are .38s, so at least you'd be closer and they should be cheap.....in fact, somewhere on this forum a set of "parts forks" are going to another member, super cheap, and you might be able to weasel some springs out of them.

I put .41s in my 94 forks....was lucky to even get them....so I know your pain!

I have used the Race Tech springs as well as the Eibach springs. Both are great.

If you are in a money pinch, perhaps you could find some used 1995+ springs. They are .35 Kg/mm instead of .30, like stock in 1989 - 1992. Heck, even 1986 - 1988 was stiffer than that. (.32 / .33)

At least you can see that you need a spring 40% stiffer than what you have. Those .30's are a joke. I still can't fathom the thinking on those.

6riders, they are .35.

Race Tech 3647 or Fredette Racing fork springs are the only springs I found to fit the 1993 - 1994 KDX200 forks. Stock 1995+ and Eibach 996 WILL NOT fit, as I have tested them myself.

.35...got it! I don't know what brand my spring are, the builder had them hiding in the "attic".....I just got lucky to get them....and for $100

OOH, I CAN tell you that they where sent from "Cannon Racecraft Inc." (Oklahoma).....Phone # (was) 405-524-7223.....try looking them up.....well, these were for the 94 forks.

Cannon Racecraft makes custom springs, as well as some stock size springs.

That's helpful. 0.35 is a considerable step up from 0.298. I will keep my eye out for any good deals for stiffer springs in the future. Did not expect the blue USD springs to work but 95+ conventionals, because I recall reading they will work plus they are the same 43mm diameter tube

But I got the new preload spacers this morning. Brother dropped them off after his night shift...they are identical in every way but with 17mm of extra preload. I wanted to go between 15 and 20mm

Dropped them in and the result is a very nice improvement in rebound and responsiveness. No more stiction or getting hung up half way up on rebound...very happy with the result!

Postigo wrote:Hi, is pretty simple if you are mechanically inclined. I bought a complete rebuild kit from Jason last year. Here is a video from rece tech: http://www.racetech.com/page/id/138

Where can I buy this rebuild kit?