84 125m To 200s Front End Conversions

[DasUberKraut]

Over the past month or so I've been stock piling 200s front end parts to convert our 125m's (Mine & The Wife's) to front suspension.



The list of what I have so far...
3 near complete fork and triple asemblies.
2 complete axle, hub, and brake assemblies.
1 All Balls steering stem bearing kit.
1 All Balls front hub bearing kit.
1 set of headlight hardware. (Looks like the 84 125m headlight hardware is very similar and may allow me to use the 125m headlights)
1 new front brake cable.



I only got one set of All Balls for now just to make sure I get one completed first. The second may be a project for our son depending if I get a 200x I'm looking at. If I do get the 200x the wife will just use my 125m that is already registered.

I will need 185s / 200s fenders eventually. I figure I'll order them when I'm near completion.

The plan is to tear everything apart and pick out the best of everything. Sandblast and powder coat. Reassemble with either old powder coated hardware or I may splurge and buy black stainless bolts for everything. That will be spendy seeing as I will have to buy full bags of every size. Good to have spares though. I just like the look of black stainless on a project. As far as I can tell the steering stops will be easy to fab up. Just need to take precise measurements of the location of studs on bottom plate of the 125m forks. Drill holes in the 200s forks and run a bolt up on both sides. I may even go so far as to cover the threads with sleeves. If there is a better way please advise.

If anyone can offer me some tips on completing the conversions that would be great. Any advice on removing old bearing races and installing new races without mangling everything to would also be appreciated.

I may even get ballsy and sell the two 125m front fenders and mud flaps, forks I guess if someone really wants them, hub assemblies would need to go too.

[tblumer]

For my 200s to 90 swap I had to notch the crosspiece in front of the steerer stem. Is the 125 frame like a 90/110?

[jr315rn]

could this be done on a 110

[DasUberKraut]

As far as I know the 110 frame is the same as a 125m.

[Jon Boy]

yeah, the 90/110/125's are about 95% the same. they have the same head/steering tube. i'm not sure about the US90's though.

[gomer202]

yeah, the 90/110/125's are about 95% the same. they have the same head/steering tube. i'm not sure about the US90's though.

i put a 200ea front end on my US90 without any modifications!

[jr315rn]

Sweet thanks man tht will be my next little project ! Could I use the same front tire from the 110

[DasUberKraut]

I was going to look up what the max tire size is for the 200s forks is. Haven't gotten to it yet. Just by looking at it. It seems like 10" is the widest the forks will allow. I'm just guessing though.

[Amater45]

Hey it's those 200s forks i sold you! haha, glad to see theyre being used. hope this project goes well!

[DasUberKraut]

One of the bearing races in my All Balls kit is just a hair taller than the other. Whiche one goes on the bottom? My guess is tall on the bottom? Anyone who used the All balls Steering Stem kit run into this? I tried to measure on the fork tube but as having isssues with an accurate reading.

[DasUberKraut]

Finally started on the first conversion.

Here is a progress pic. Just waiting to determine which bearing race goes where before I mount a set of shock forks in. The races are already in the freezer.
I may email All Balls and see what they say too, just in case I don't get a quick response on here. I never have good luck with customer service though.

[oscarmayer]

it's a direct bolt on.... done it many times.

[DasUberKraut]

it's a direct bolt on.... done it many times.

To which to de you refer? Also have you used the All Balls kits? Do you know if the taller race and bearing goes on top or bottom?

[DasUberKraut]

Nevermind. The shorter race is on top as I thought. Customer support at All Balls is quick! They responded to my e-mail in about 10 minutes!!!

[oscarmayer]

i always just re-use the stock bearings myself. clean everything up like new, take some lith grease, spap it in the races, insert the bearings 1 at a time on the top, then do the same to the botom and install neck. sometimes take sa few tries to keep bearings in place. but works well.