Rebuild baja forks
- Thread starter madtom421
- Start date
Just did my MB-165 yesterday. Per other posts here I used a Yamaha TTR90 (2000-2007) seal. There are others you can use but this Yamaha one seems to be very common was available on ebay. You will need to remove the forks from the bike so you can get at everything and to dump out the old oil. There is a socket head screw on both the top and bottom of each tube that need to be removed. Many people here seem to like to use a thicker oil for a stiffer shock. For oil I used 51ml of type F tranny fluid in each tube. This has a ISO of around 42. Search this forum and you will find many posts about the subject. Dont over fill.
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Ive changed the forks and triple tree on my sons Warrior. Used a Honda XR75 set up but it does require some machining to replace the center stem. In my case I had to remove the Baja center stem, which is longer and wider, from my stock set up and cold press and weld it onto the Honda lower suspension bracket. PITA to do but it works nice and allows for a larger thinner tire and rim, front Honda drum brake and with a little work a Honda gear driven speedometer. He loves it and it has a nice look. Add in the real tank and wider rear tire and its a whole new feel.
To give a little more detail, (I should of took pictures ) I'm trying to replace leaking fork seals in a baja warrior mb200, I ordered ttr90 fork seals 2000-2008, the inner diameter seal against the shaft is perfect, but the fork seal isn't large enough to press into the fork and it's not tall enough to seal against the snap ring. It just floats around. Can anyone suggest a larger seal? I destroyed the first seal hopefully I get get the other one out intact to size up
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the stock forks suck, I got tired of the clink clink bottoming noise and installed these Honda xr80 forks. I think pre 1980 the kind with the axle on the bottom. lots of them on ebay. it was a tight fit in all the way to the top... I shouldnt have done that. instead of drilling and reaming all that tube, you should be able to cut most of the lower triple tube away, since the longer fork tube will go all the way to the top triple plate
stock internals:
stock internals:
you could measure the seals if there's no numbers on them, if you know the dimensions (metric) ID OD and thickness you can type them in a web search and get tons of results. allballs.com has a dimensional cross reference as well.
the forks will only fit into the clamps about 2 inches then hit the seam inside the tube. Unless you can ream the entire tube cut it off above clamp and allow the new upper/inner tube to slide all the way up to the top clamp. theres even a threaded hole in the new forks to bolt up to the top plate.
the forks will only fit into the clamps about 2 inches then hit the seam inside the tube. Unless you can ream the entire tube cut it off above clamp and allow the new upper/inner tube to slide all the way up to the top clamp. theres even a threaded hole in the new forks to bolt up to the top plate.
Rebuilt the baja warrior forks over the holiday these metric fork seals were a perfect match. The mb165 forks must come with smaller outer diameter fork tube the ttr90 seals aren't big enough for the warrior. Used 50-51 ml of fork oil I had laying around. Forks are much firmer feeling.
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