Replacing Fork seals on a DR200

[Baldyman]

I have just taken the forks apart and the old seals are screwed. I want to replace them myself. Do i need a special tool to install new seals and does the fork oil get poured in from the top or the bottom? ( Do i need to take the whole fork assembly off?)

[Motu]

I always strip it whole fork because if the seal is stuffed it sucks crap into the fork.You might need a tool to lock the damper rod,but I use air tools so have no problem.Fill from the top with the correct amount (in your manual....you do have a manual before attempting this repair of course??)

[mc4aregreat]

you will need a manual. I havnt been able to find a manual for the dr200, but i found one for the dr125 and has a chapter at the back for later dr125 that look identical as my 200.While specs will be different i use it as a guide, and after reading the manual, the fork work has certain steps in order. to many to write.never did the forks on mine.never even noticed the wear until i got a new drz250.

[WINJA]

I have just taken the forks apart and the old seals are screwed. I want to replace them myself. Do i need a special tool to install new seals and does the fork oil get poured in from the top or the bottom? ( Do i need to take the whole fork assembly off?)

I USE THE OLD SEAL TO TAP THE NEW ONE IN, THAT WILL PROTECT THE NEW ONE FROM DAMAGE , I ALSO USED EXHAUST TUBE TO SLIDE OVER THE FORK TUBE AND TAPPED FROM THE END , PUT OIL ON IT BEFORE ASSEMBLY,
IF THEY LEAKED FEEL FOR STONE CHIPS ON THE CHROME ANY RAISED BITS CAN BE FLATTENED WITH A BIG ALLEN KEY BEING RUBBED ON IT HARD

[Baldyman]

Thanks guys for the info, it has been a great help. just another question. I have taken the rubber caps of the top of the forks and there is a metal disc underneath. I assume i need to remove this disc to expose a filling hole. Is this correct and if so how do I take tos disc out? Ther does not appear to be any slot or anything. Am I missing somthing? ( Please don't say a brain.)

Cheers

[mc4aregreat]

Using a metal rod of suitable diameter,push the top plug down against spring pressure until the circlip can be displaced from its groove with a suitable sharp instrument such as a very small flat bladed screwdriver.when the circlip has been removed,gradually relax the top plug. keep your face away in case it flys out.

[Baldyman]

Thanks for the help - I got it sorted.

Cheers

[F5 Dave]

To lock the damper rod & undo the hex bolt in the end (near axle) either you can make a long rod with a bolt welded to it to fit many (most Suzuki) damping rods. Or just put the spring in & compress it, maybe held in a vice & the wall. This puts enough pressure to undo the bolt. Most of the time. Air tool never fails.
Don’t forget the circlips on the seals.

Once undone the slider pulls out of the tube, usually taking the seals/bushing with it depending on the design.

I have some plastic conduit the right size or adapt to push them back in again.