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Upgrade suspension increase ride height

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Hi,

Want to upgrade my 2001 XR200R with an 84 fork and rear shock. Found forks for reasonalbe price, but haven't found rear shock yet. Question: how much will the seat height increase?

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The long forks are 84-91, same years for the rear shock, and the 84-85 XR250R shock.

Per Honda specs the difference in travel will be 1.8" on the front and 1.3" on the rear, I expect the change in seat height to be about the same.

Picture of difference between 01 and 90 models:

01vs902.jpg

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I'm seeing a lot of 84-91 forks on ebay, but hardly any rear shock. Why is there a shortage of shock?

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It's been almost two years, and I'm still have n't found a long travel shock for my 200. :(

Edited by Terminatr

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I'm finally getting a long shock with remote reservior for my 2002 XR 200. Where do I mount the remote reservoir?

Edited by Terminatr

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If it is the shock discussed in previous post (has long hose) it mounts on the left just inside the rider's leg.  The Honda Service manual, and I think Clymers, show the hose routing. Here is a poor pic of a reservoir, you can see it mount horizontal inside the left fram tube,  with the compression clicker forward (black knob).

 

XR200R Shock Reservoir.jpg

 

The best source for a bracket is any of the model chassis that used the shock.  I have been able to remove brackets with a cut off wheel in a Dremel, and then weld them to another chassis.  Several tack welds works.  You also need the two reservoir mount clamps, one is visible in the pic at the aft side of the frame tube.

 

There are other early mono shock dirt bikes that also used remote reservoirs and some of those brackets might also be adaptable.

 

On edit:  I found this in a thread several years ago about reservoir mounting options, unfortunately I don't have the members name for credit:

 

I found a solution in the rubber reservoir brackets from a 1984-86 CR250/500 (www.bikebandit.com can help)  at a junkyard for $1, complete with correctly shaped clamps. Sadly, my local bike wrecker is fresh out of scrapped CR500s and Honda no longer carries the part. It looks factory and doesn't require welding the frame.

Rubber  50250-KA2-830  85-86 CR125/250/500

Rubber, sub tank 50251-KA2-830  85 CR125/250/500

Band, sub tank 50252-KA2-730  84-86 CR250/500

 

Edited by Chuck.

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1383653606903.jpgI need some help. I have an 01 xr200r i got for my son. it runs like a dream. BUT..... the rear shock is shot and a new one will cost more than I paid for the bike. So, my question is this, does anyone know if one from a '82 XR250r will work? Thanks, Wayne

 

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attachicon.gif1383653606903.jpgI need some help. I have an 01 xr200r i got for my son. it runs like a dream. BUT..... the rear shock is shot and a new one will cost more than I paid for the bike. So, my question is this, does anyone know if one from a '82 XR250r will work? Thanks, Wayne

 

I don't think so. Your bike has the short travel shock (1993-2002 model year).

 

I'm about soon to upgrade my 2002 shock. It will be for sale after Christmas.

Edited by Terminatr

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You can use the 81-83 XR200R shock but I recommend the 84-91 shocks as noted above. 

 

The 81-83 XR200R shock has a short 10" hose, is 13 1/4" c-c, and only has one clicker.

The 84-91 XR200R and 84-85 XR250R shock has a long hose, is 13 1/2" c-c, and has compression and rebound adjusters.

 

I don't know the length of the 93-02 shock but based on ride height difference from the 84-91 models I suspect it is about 13" or a bit less.

 

Could someone with a 93-02 XR200R provide the center to center length of their shock?

 

Bike height comparison between 86-91 & 93-02.

 

01 vs 90 2.jpg

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The 93-2002 shock is 13 1/4 inch long, the 1984-1991 XR200R shock is 13 1/2 inch long, the 1981-1983 xr200r shock is exactly 13 inches long. I have three of the 81-83 shocks here off the bike, there is no doubt of there length.  The 81-83 shock is not suitable for use on the 1984-2002 frame. The difference in seat height between a 1984-1991 xr200r and the 1993-2002 xr200r is exactly 1 1/2 inches.

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The 93-2002 shock is 13 1/4 inch long, the 1984-1991 XR200R shock is 13 1/2 inch long, the 1981-1983 xr200r shock is exactly 13 inches long. I have three of the 81-83 shocks here off the bike, there is no doubt of there length.  The 81-83 shock is not suitable for use on the 1984-2002 frame. The difference in seat height between a 1984-1991 xr200r and the 1993-2002 xr200r is exactly 1 1/2 inches.

 

Thanks for the info, when I had early XRs I had no reason to measure the shocks and  the 13 1/4 value is from previous postings by others in several threads.  When I bought my 01 it didn't have a shock so I was also missing that number.

 

A bit of confusion has existed on the differences between various 86-02 models and Clymer's contributed to the problems by showing three different suspension specs for the 86-02 models.  I researched parts fiche on the suspension components and verified that Honda specs are correct and Clymer's specs are wrong. Here is a link to the results: http://www.thumpertalk.com/topic/860575-xr200-chassis-and-suspension/#entry9355697

 

The 93-02 shock length of 13 1/4 seems long based on the appearance of ride height in the above photo. But I think differences in static sag, and/or bike positioning  is exaggerating the appearance of the newer bike being much lower than the older one.

 

Honda's specs for ground clearance, suspension travel, and seat height seem to fit 13 1/4" because at full extension the 86-02 linkage ratio is about 4:1 so a 1/4" shorter shock would lower the bike about one inch, which you can see in the Honda ground clearance specs for the models using the two shocks.

 

Years .  Ground Clear.

86-91…....… 12.0

93-02……… 10.9

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Ok! I finally got both long shock and long fork installed on my '02.

 

A question about fork height. THere's a line about half-inch below the top of the fork tube. Am I suppose to line up the

top of the tripple clamp with this line?

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I got an 85 fork from Ebay. When I compare it to my 02 fork, they're identical except the springs and the rod thingy. The rod thingy is only $30 brand new. So, if you're looking to upgrade your 93-02 fork and can't find one in good shape, you can just buy a set of long springs and the longer rod thingy from the dealer.

 

My 85 ebay fork has got a lot of cross hatching on the inner tube--like somebody took fine wool to it. And it overall looks very beat up. I ended up swapping the rod thingy and the spring to my 02 fork. Because my 02 fork is in excellent condition.

Edited by Terminatr

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The longer travel 84-91 damper rod has been unavailable for many many years now. It is listed as obsolete by Honda. This was a common, inexpensive fix for years but no longer. I believe the fork spring is also now obsolete.

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The longer travel 84-91 damper rod has been unavailable for many many years now. It is listed as obsolete by Honda. This was a common, inexpensive fix for years but no longer. I believe the fork spring is also now obsolete.

 

Didn't realize that it's no longer available.

 

By the way, can somebody tell me if I need to raise or lower the fork tubes?

Right now, the top of the fork tube (excluding the cap) is 1/4 inch above the triple clamp. My race sage is set to 3.3 inches. When I go into a loose sand corner, the handlebar wants to turn to the inside of the corner; the bike wants to high-side me.

 

For example... I go into a left turn. I start to lean the bike left. The handlebar immediately wants to turn left all the way. If I don't have a good grip and elbow high, the front wheel would plow and I would fly over the handlebar. I dunno if this is normal handling, but my old suspension didn't do this.

Edited by Terminatr

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Depending on year it is more than the rod. Here are some fork part numbers that show what years changes were made by Honda.

 

XR200R Fork part numbers:

Damper rods:

84-85  damper rod (pipe, seat)  51440-KK0-004

86-91  damper rod (pipe, seat)  51440-KT0-671

93-02  damper rod (pipe, seat)  51440-KT0-691

94-02  spacer  51402-ML0-004

 

Stanchions:

93-02 Stanchion  (pipe)  51410-KT0-691

84-91 Stanchion  (pipe)  51410-KK0-004

 

Sliders:

84-02 R Slider (case)  51420-KK0-014

84-02 L Slider (case)  51520-KK0-014

 

Springs:

84-85  51401-KK0-004 & 51402-KK0-004

86-88  51401-KT0-671

90-91  51401-KT0-831

93-02  51401-KT0-691

 

Rebound Springs:

84-02  51411-KK0-004

 

Spacers:

94-02  51402-ML0-004

 

As you can see from the above the stanchions also changed in 93 with the damper rod.

The two springs listed for 84-85 together provided two rates, other springs I have found in XR forks had coils wound with two pitches so were also two rate springs.  Aftermarket springs were, and may still be available.  I have used  springs from 84-88 XR250Rs,   as well as aftermarket, and there may be others that will fit. Some dimensions of springs that I have:

ODs: 1.15-1.24"

Free Lengths: 23-23 1/4"

 

Two rate springs do offer a plush ride and bottoming resistance, and a lot of riders like them but I find the sudden transition to the high rate annoying, and the low primary rate makes setting sag more difficult. 

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