1989 fork service

greener200h · Post by **greener200h** » 09:18 pm May 15 2016

I have 1998 kdx 200 with what I think are 1989 front forks. P O smashed originals and relaced with the 89s. has single piston brake, brake pads are from an 89 says my local parts house. I took the cap off the tube and no piston rod. the outside bottom of fork has allen head bolt ? no clicker adjustment. can't seem to find fork service directions. need help. refill fluid procedure ? prime ? no piston rod on this model ? i don't have service manual for E, only for H and it is different. PLEASE HELP. much appreciated.

dlorence · Post by **dlorence** » 02:44 am May 16 2016

10 W fork oil 140 +_

greener200h · Post by **greener200h** » 12:32 pm May 16 2016

thanks. Is the 140 the level in mm down from compressed fork tube ? any need to prime / get air out ? the '98 said 5wt, so thats what i bought. Is that too light / soft for the '89 ?

Post by **KDXGarage** » 12:17 am May 17 2016

No compression adjuster is 1986 - 1988. Are you sure it does not have a screw to turn?

6 Riders · Post by **6 Riders** » 01:00 am May 17 2016

Jason wrote:No compression adjuster is 1986 - 1988. Are you sure it does not have a screw to turn?

Check to see if there is a rubber plug inside the hex socket, there should be one and the screw is under that.

greener200h · Post by **greener200h** » 05:17 pm May 17 2016

I checked for adjuster. no rubber plug and definetly no adjuster. must be '88. got to love those p o' s who have no idea what they got. is the 10w and 140mm down still good for the '88 ? THANKS for all the info. I love this site and everyone on it. what a great help it is. KDXRIDER.NET

Post by **KDXGarage** » 11:22 am May 18 2016

10w is the standard oil for the 1986 - 1988 forks also.

I don't have the owner / service manual handy, but 140 or 125 should be OK. The stock springs are pretty dang soft in the older forks.

greener200h · Post by **greener200h** » 02:01 pm May 18 2016

Thanks Jason for your help. are the triple clamps probably from the '88 ? or are the '88 and '98 clamps the same ? will a 220 front end direct bolt on ? I learn more every day. THANKS

Post by **KDXGarage** » 12:41 am May 19 2016

PICS STOLEN FROM EBAY SELLERS

1988 and 1998 would be interchangeable, but it would depend on whether or not the wreck damaged the stock clamps. Which does yours look like on the two pics below?

1986 - 1988 style:

1989 - 2006 stle (as far as bolt vs. nut)

greener200h · Post by **greener200h** » 02:24 am May 19 2016

my triple clamps look like the bottom picture '89 - '06. so I probably have stock '98 clamps with '88 forks. I presume I could upgrade to newer 200 or 220 forks into my '98 tclamps. In your opinion is it worth it to go from '88 non adjust to newer w / at least comp adjustability ? I would get better brakes. Do the later years have comp and rebound ? when did that start ? I may be over thinking all this. I need to get bike all together and ride and see how it handles / feels. after all im an older guy who rides slow mostly single track trails. maybe I don't need adjustability. I do like plush suspension.

greener200h · Post by **greener200h** » 02:41 am May 19 2016

I forgot something. what are the caps on top of the '88 forks for ? I took one off thinking they were bleeders but they don't seem to be. am i crazy or stupid ? the other cap seems stripped. I couldn't get it off. will try again tomorrow.

Post by **KDXGarage** » 02:47 am May 19 2016

Big, black, plastic caps? If so, they are just valve caps. Air bleeders in the modern world. Take it off and deflate the air out (with the forks fully extended on a stand, or as best you can)
If you can, e-mail me some pics at:

administrator at kdxgarage dot com

A picture is worth 1,000 words.

greener200h · Post by **greener200h** » 02:59 am May 19 2016

bare with me, two finger typing. silver metal cap w / 10mm head I believe raised in the center of fork cap. underneath it is flat w / dark metal ? ball in a hole. can not seem to push in w / finger nail. hole seems plugged. no seal / rubber on cap. no apparent valve. looks like it should be bleeder port. will inspect more in daylight.

greener200h · Post by **greener200h** » 03:16 am May 19 2016

don't hold your breath for picture. still using old flip phone. barely computer literate. have'nt evolved that far yet.

Post by **KDXGarage** » 03:32 am May 19 2016

HA! OK.

Maybe you have some sort of bleeders on there. 1986 - 1988 has a big plastic valve cap on it, and looks like a typical Schraeder fitting.

greener200h · Post by **greener200h** » 03:45 am May 19 2016

Ok THANKS maybe P O replaced plastic w / metal caps. something so simple turns into difficulty. what's one more problem. almost done with forks for now. THANKS again for your help.

Post by **KDXGarage** » 04:13 am May 19 2016

You're welcome.

david · Post by **david** » 08:58 am May 19 2016

This what my E series looks like.

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Friedom · Post by **Friedom** » 12:47 pm May 19 2016

I'm in Tucson and have a whole 92 front end you can have (triples, forks, wheel, caliper, rotor, axle and new boots) if it's of any use. Too bad we're not a little closer!

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greener200h · Post by **greener200h** » 03:15 pm May 19 2016

Jason was right. had shraeder valves. they were sealed up with epoxy. one was snapped off the top of fork cap and just glued back on. some people and their ideas. I cut off the remaining valve assemblies flush with the cap tops. drilled and tapped the caps. installed some Motion Pro fork bleeders I saved from an old kx250 I traded for my kdx200. problem solved. YEAH ! now refill forks and be done with front end. Thanks Jason. Thanks Friedom for the offer.that is great. let me get bike running and see how it feels. might be just fine for my style ? of riding. one step at a time.THANKS EVERYONE !

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