'83 Honda 200e front shocks/fork

[Jd110]

[emoji847] hi guys. Big red's got down time. Shock boot spilt in two some time ago. I've kinda babied it, since. Not sure what will end of it, yet. I'd like to start by taking it apart to have a look. Both shocks still compress ok, they don't go up all the way, unless I lift the front end.

I haven't had any luck finding a certain thread. I vaguely remember it, but it did show them disassembled.

I'm also having a difficulties viewing the service manual. I'm going to get that printed today, hopefully.

If someone could help me find it, I would really appreciate it and think I'd be ok-for awhile.
My great tape job lost its function in notime. https://uploads.tapatalk-cdn.com/20171103/0621cc449863cfd255ca9f1671125363.jpg

[schlepp29]

Looks like your bushings wore out. I had a 200 big red that did the same thing. I found out that is a common problem for these models. Some guys put different front ends on them. Well hope you find a solution

[Jd110]

Looks like your bushings wore out. I had a 200 big red that did the same thing. I found out that is a common problem for these models. Some guys put different front ends on them. Well hope you find a solution

Thanks, a different front sounds like a good idea to me, too. I'd like to look into these original ones, first. See what's going on in there and if they can be rebuilt. I don't jump it or anything like that. In fact, I really don't need suspension there. But welding it is very last resort.

[schlepp29]

Yeah I've seen them welded before some cobbed and some done nice. I'd still like to put mine back together as well. I've wondered with the right material if I could have some made on a lathe. I wondered about brass or a good nylon. I don't blame you for wanting to keep yours it looks super clean from what I could see

[Scootertrash]

I swapped the front end out on one for a customer. I believe it was a 200M front end that was used for a replacement, I'd have to find the thread. That front suspension system sucks and no (or very, very few) parts are available to rebuild them. IIRC they only used those front ends for 2 years. But I could be wrong.

[tripledog]

If you decide to swap out the front forks, this link may be helpful. http://www.3wheelerworld.com/showthread.php/135875-1984-200es-with-a-200m-front?highlight=200m+front+end+swap

[Jd110]

Yes, I'd be interested in seeing your thread, scooter-thx. I agree with a swap and remember the numerous times it has been mentioned about 82-83 being a poor design. If it's easier for now, to fix these, I'd like to.
Thx tripledog for the thread. I didn't see that one in my search. This might be like 'looking for a needle in a haystack', but I saw a thread a time ago that showed the differences in all/most 200-series (s,m,e & es). I want to say you were involved in that discussion or at least around when that thread was brought up in another thread. Thank you guys, for the info.

[Jd110]

https://uploads.tapatalk-cdn.com/20171107/2618e4ea353c9ac65c75af55240b683a.jpg

https://uploads.tapatalk-cdn.com/20171107/3fe7b5d79b2b495a4a89bbfe98b0bfbc.jpg

https://uploads.tapatalk-cdn.com/20171107/40b0a30f6bb72eff6c3e991a2829258c.jpg

https://uploads.tapatalk-cdn.com/20171107/cf452f890e5bb648baca4dc920d0aa19.jpg
They cleaned up ok. Little water in the right. None in left side. It'd be nice to just grease and put back together. What would you guys do?
I've been looking for another front end and will continue searching.
Also, would this be ok to use?
https://uploads.tapatalk-cdn.com/20171107/95e4b3695ef6d1404502f3c50d815afc.jpg

[schlepp29]

Slide your lower leg on and see how much play there is.

[Jd110]

Slide your lower leg on and see how much play there is.

I just went to check: left leg has very little play. Right has about 1/8" of play. Good? Thx schlepp.

[schlepp29]

No problem, can you see the nylon bushings inside the lower legs? If so try and pull those out. Those are the pieces that are wore out.

[schlepp29]

The left leg has alot of pitting which will wear out another bushing. You may be better to find another front end. Good luck jd.

[Jd110]

I appreciate the insight. Found some bushings:
https://m.ebay.com/itm/Honda-ATC-OEM-NOS-shock-fork-guide-200es-200e-1982-1983-1984-rebuild-slide-26-76/263081462839?_trkparms=aid%3D111001%26algo%3DREC.S EED%26ao%3D1%26asc%3D20160908105057%26meid%3D370bb 4b6414943a6830b7538785b27db%26pid%3D100675%26rk%3D 1%26rkt%3D15%26sd%3D263081462839&_trksid=p2481888.c100675.m4236&_trkparms=pageci%253A08628df9-c3db-11e7-8191-74dbd180aa15%257Cparentrq%253A975f26e115f0aa16af62 0daffffb7453%257Ciid%253A1
Haven't located any boots, yet. Considering the way I use it and how long new bushings would last (idk?). It might cost a couple hundred to get it going for awhile. I'll ponder it today.

[schlepp29]

I wondered if that was possible

[Jd110]

https://uploads.tapatalk-cdn.com/20171107/2106c28de6c7033567028eecf8f6997f.jpg
I got them smoothed out the best I could, this morning.
Called dealer and boots will be here Friday. Ordered 4 bushings, too. Total cost-$180. I figured it's better than waiting for an upgrade. Thank you for your guidance 29. I was going to grease and go until you mentioned the play.
Thx dude, sounds good. Im not sure, though. My skill level, might make a mess versus running them the way they are. I may try it. Which would be better, JB weld or solder?

[Jd110]

you can use solder or copper electrolysis to fill the pitting then sand them smooth. even jbweld will work for a long time if you follow directions

I really like the idea of a filler. Went back and sanded with wd-40. It's not great, just better. I feels noticeable, still. Here's a close up.
https://uploads.tapatalk-cdn.com/20171108/cd76b383a20b0ed2918deccb04338127.jpg

How would you apply solder to this?

Ps. Nagging question in my mind: Is making it baby smooth going to make a big difference, longevity wise, in this?

[Scootertrash]

Yes, I'd be interested in seeing your thread, scooter-thx. I agree with a swap and remember the numerous times it has been mentioned about 82-83 being a poor design. If it's easier for now, to fix these, I'd like to.
Thx tripledog for the thread. I didn't see that one in my search. This might be like 'looking for a needle in a haystack', but I saw a thread a time ago that showed the differences in all/most 200-series (s,m,e & es). I want to say you were involved in that discussion or at least around when that thread was brought up in another thread. Thank you guys, for the info.

I will see if I can dig up my thread. ;)

[Jd110]

Got the bushings out:
https://uploads.tapatalk-cdn.com/20171112/04bf0143e356636a06be43660326d8ba.jpghttps://uploads.tapatalk-cdn.com/20171112/308efe7a3da4fc4d680ebbc206ad33d9.jpg
Fork sliders are getting painted:https://uploads.tapatalk-cdn.com/20171112/3f2b66f33e28c8dd87c491259a937db0.jpghttps://uploads.tapatalk-cdn.com/20171112/6d882264d9cb951255808dac611189a9.jpghttps://uploads.tapatalk-cdn.com/20171112/2df136932439adda599caa51e960b1e6.jpg
Used metal polish and 1500 grit, today on the fork tubes:
https://uploads.tapatalk-cdn.com/20171112/cad18bb4bce013fcf3a1dfab9581c9f4.jpgwould be nice if it were better-it'll do without refacing.
Those new bushings arrived fast! There going in as soon as the paint dries.
https://uploads.tapatalk-cdn.com/20171112/c15a2596a51fa7717691f8f79ae2fdf4.jpg
Found this yesterday, so I'm glad to be using the original forks.

[wonderboy]

I appreciate the insight. Found some bushings:
https://m.ebay.com/itm/Honda-ATC-OEM-NOS-shock-fork-guide-200es-200e-1982-1983-1984-rebuild-slide-26-76/263081462839?_trkparms=aid%3D111001%26algo%3DREC.S EED%26ao%3D1%26asc%3D20160908105057%26meid%3D370bb 4b6414943a6830b7538785b27db%26pid%3D100675%26rk%3D 1%26rkt%3D15%26sd%3D263081462839&_trksid=p2481888.c100675.m4236&_trkparms=pageci%253A08628df9-c3db-11e7-8191-74dbd180aa15%257Cparentrq%253A975f26e115f0aa16af62 0daffffb7453%257Ciid%253A1
Haven't located any boots, yet. Considering the way I use it and how long new bushings would last (idk?). It might cost a couple hundred to get it going for awhile. I'll ponder it today.

Next time, before jumping on an e-bay auction, check Honda themselves. Honda still stocks those bushings. They are less than $7 each. I hate the e-bay guys who rip people off. He intentionally put a sticker on over the Honda part number too so that you can't see exactly what the part number is that he has... shady.

#10 at this link:
https://www.cyclepartsnation.com/oemparts/a/hon/506f8cbff8700229747b95b2/front-shock-absorber

[Jd110]

Ya, I guess I should have checked.

[Jd110]

It went back together, well. Works just like it should.
Ended up spreading a thin layer of grease on the outside of the bushings, inside of the slider and springs. Used a tad bit of elastomeric silicone-lol.
Since the condition of these were pretty good to begin with, I'm glad I saved them and very pleased with the results.
https://uploads.tapatalk-cdn.com/20171116/b04174590d89c8f330abe2a7efa86a15.jpg
https://uploads.tapatalk-cdn.com/20171116/dd7d8f4e702bf9d837be0c13b7a0ddb9.jpg

[AMK]

...sweet...

[schlepp29]

Looks nice jd

[Big G]

Very nice work. Nothing like a fresh set of front suspension!