Disassemble: If you have TW 200 Manual, use it. If not, search for free pdf TW 200 manuals on line to download.
1. Support motorcycle with front tire off the ground.
2. Remove front fender/brake cable/reflectors
3. Remove front wheel. It's possible to leave speedo cable on and move tire out of the way after axle has been removed.
4. Loosen fork caps located on top of forks near handle bar & instruments. (do not remove caps yet.
5. Remove upper fork clamp bolts. 1 ea Left and Right side near fork caps.
6. Remove lower clamp bolts. 2 ea Left and Right side.
7. Remove each fork. If too hard to remove, gently tap a large flat tip screwdriver or similar tool into clamp slot to spread clamps just enough for fork tubes to move. Fork should then slide out easily.
8. Remove fork boots, then with fork on bench and slightly elevated upward (on cap end), remove pre-loosened fork caps, inner slide and spring.
9. Tilt top of fork down into bucket and drain fork oil.
10. For next step you will need special tool. Compress inner tube all the way down. With T-handle approx. 16-20 inches long with 19mm "holder" attached to end, insert into inner tube until it connects and is seated with damper rod lock nut.
Note: A homemade device can be made to remove damper rod nut. Use a 19mm nut, locked onto a bolt of similar dimension. Then use socket on end of extensions that will reach, to insert into damper rod nut.
11. At lower end of fork tube, place Allen wrench on hex bolt.
12. Loosen hex nut and inner damper rod lock.
13. Once hex nut is removed, inner fork tube, damper rod can be removed easily. Remove damper rod. Be careful to keep misc. components (washers, springs) in order.
14. Remove dust seal cap
15. Remove wire clip which secures oil seal in place.
16. With small wood block to protect lower outer fork tube, use screwdriver to pry oil seal from lower outer fork tube.
Assembly:
1. Use oil seal driver to insert new oil seal into place. One can use a larger matching socket to accomplish this without the tool, but use caution not to damage oil seal.
2. Manual states to insert inner fork tube components and slide oil seal over and down inner fork tube, but can be done as mentioned here if caution is used.
3. In both instances, lube inner fork tube with lithium grease prior to inserting the oil seal or inner fork tube if seal in seated first.
4. Insert oil seal wire clip, then dust seal.
5. Fill fork with 10wt fork oil (about 8.2 U.S. oz), exercise inner tube to circulate fork oil, and check level per manual specs.
5. The rest should be easy, just reverse the order of when disassembled.
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