Cheap fork upgrade, gain over 20% travel for under $100

[TxTaoRider]

I'm sure someone has already posted this but...

For less than a 100bux I increased the front travel on my tbr7.

I bought a complete set of forks from a 1980 honda xr200 (not "R") for 60bux off ebay. I pulled the damper tubes which are 1.5" longer than the tao's. I swapped my plastic sliders from my tbr7 to the honda dampers as they are a little larger in diameter. Then install them in the tbr7 tubes and like magic I picked up 1.5" of travel.

It's possible that your stock springs will bind before complete compression because they are made out of thick diameter with allot of coils. You will also have to make your spacers a longer, but you may not need as much preload, due to the longer travel so your overall ride should be smoother.

Now what I did. The 80-82 honda uses 2 springs, a long bottom one and short one on top separated by a washer. I measured the long bottom spring and it has plenty of coil spacing for over 9.5" travel. So I only used the long spring, and made a longer spacer. I ended up about 8mm of preload.

I filled it up with 10wt fork oil 120mm from top (no springs, fully compressed).

Pros: it rides so much smoother.

Cons: Bike is 1.5" taller in front (.75" at your feet)
Brake lines may be a little short if using bar risers or tall bars.
Fork boots set a little lower.


I havent added a brace yet, but I will soon.

Overall, it's a great cheap improvement.

[Skyd]

wow - very cool. I have an XR200R in the basement actually a bit newer than the XR200 forks you got, but that's interesting none the less.

[TxTaoRider]

Originally Posted by Skyd

wow - very cool. I have an XR200R in the basement actually a bit newer than the XR200 forks you got, but that's interesting none the less.

Probably wont work. The non "R" use a 31mm fork, the "R" uses a 35mm I think.

[Megadan]

That would put the front end travel at 8 to 8.5 inches.

[TxTaoRider]

Originally Posted by Megadan

That would put the front end travel at 8 to 8.5 inches.

Yes. It measures 8.0" not including compressing the top out spring, so the 8.5"-8.6" that honda specs (depending on source material) is about right including their travel added. The new damper tubes measured about 1.5" (actually 1.45") longer than the factory dampers.

In theory, since it's over 20% in additional travel, you can go 20% less in spring pressure with the same bottoming resistance.

[Megadan]

Originally Posted by TxTaoRider

Yes. It measures 8.0" not including compressing the top out spring, so the 8.5"-8.6" that honda specs (depending on source material) is about right including their travel added. The new damper tubes measured about 1.5" (actually 1.45") longer than the factory dampers.

In theory, since it's over 20% in additional travel, you can go 20% less in spring pressure with the same bottoming resistance.

That would definitely make it a better off.road bike. Not sure if I will be doing this particular upgrade, but it is pretty sweet. I like seeing other people do mad scientist experiments

[Megadan]

Also, damping rod is part number 51440-446-003

This does not include any other parts, but many of the missing bits can be transered from the hawk anyway.

[TxTaoRider]

Originally Posted by Megadan

That would definitely make it a better off.road bike. Not sure if I will be doing this particular upgrade, but it is pretty sweet. I like seeing other people do mad scientist experiments

It puts the bike forks up to 1980 technology. Lol

What is nice, is the parts are cheap on ebay, and if someone wanted to do the swap it could be done without having to remove the seals. In fact it could be done on the bike with a good magnet, but might be a little messy.

This summer I'll try relocating bolt holes in the swingarm along with a heavier spring to gain some travel there too.

[TxTaoRider]

Originally Posted by Megadan

Also, damping rod is part number 51440-446-003

This does not include any other parts, but many of the missing bits can be transered from the hawk anyway.

I think the stock chinese springs may bind before full travel so you might be better of getting the whole assembly with springs.

Fyi, if you can find 1983 cr80r damper rods, they'll go about 8.9" travel. They are super rare and out of production. Also I think adding that much length to these forks may make them feel real flexy.

[Megadan]

Originally Posted by TxTaoRider

I think the stock chinese springs may bind before full travel so you might be better of getting the whole assembly with springs.

Fyi, if you can find 1983 cr80r damper rods, they'll go about 9.5" travel. They are super rare and out of production. Also I think adding that much length to these forks may make them feel real flexy.

I would get some custom single rate springs at that point anyway. Only runs about 150 bucks

[TxTaoRider]

Originally Posted by Megadan

I would get some custom single rate springs at that point anyway. Only runs about 150 bucks

At 190lbs using the single lower spring is pretty close based on Racetech's preload/sag measurements for an MX style bike. I'm sure its be fine for someone a heavier that doesn't do many bigger jumps and besides, they were included in the the price of the forks. Lol