xr400 front end swap

[brademan76]

Someone local is selling a full front end from an '04 xr400 for $200. I've got an E-series with USD forks that leaves plenty to be desired even after re-springing. Anyone with experience with this swap? I'm wonderng the specs on the steering stem/bearings of the xr400 and how easily it could swap into the neck on the kdx...

[Chopperpilot]

Have you compared your USD setup to a factory KDX forks? I realize that the XR400 forks are the creme de la creme with adjustable compression and rebound...... but the 43mm conventional fork flex is still there. That's what I couldn't stand. If your USD forks still leave a lot to be desired, and you've sprung them for your weight, have you considered re-shimming the compression stacks in them? What USD forks are they? I put what is probably the easiest, but worst? USD forks on my 2001 KDX (1993 KX 250) and they are leaps better than the factory setup with just the little shim work I did rebuilding them. What is your USD forks doing that you don't like? too harsh over small stuff?

[Chopperpilot]

I would assume though, to actually answer the question you asked...... I'd think you could get a KDX triple clamp setup and put the XR forks into them. Looking up the specs, the XR400 uses 43mm conventional forks just like the KDX did, and that's the chrome tube measurement, so the KDX clamps should work? (I don't personally know for sure though) If you can put a caliper on the XR400 forks where they clamp at, I can compare on my 2001 KDX front end I took off. I also have a spare KDX triple clamp set (I was using it for mocking up my USD setup) that I can send you (but shipping from Alaska might make it not worth it, you can find them on Ebay).

[brademan76]

Yes i've got a later model 220 with the normal 43mm forks. The USD forks/triples from the 93-94 model are completely different. The XR front end is triples, wheel/tire/axle, brake, bars, etc. So, I'm asking IF anyone knows if i can just drop it into my neck or if I'll need to put a different stem in or what. Buying different model KDX triples kinda defeats the purpose.

I'm going to see if the guy can get me a stem lenght and OD and thickness on the bearings to see if they'll be compatible in my kdx neck.

[Chuck78]

Those are great forks to upgrade to, but I don't know about the steering stem length. KDX 95-06 triples can be had dirt cheap and will make it a direct bolt in, but you'll need the XR front wheel and XR or 95+ KDX (94+ KX?) brake caliper.

How much do you weigh? If pushing much over 200, I'd say go for a 96+ KX RM YZ CR fork swap for 45mm-48mm forks. They all require steering stem swapping or other work though along with revalving for woods.

[KDXGarage]

viewtopic.php?f=104&t=25774&p=226963&hi ... 00#p226963

[brademan76]

Those are great forks to upgrade to, but I don't know about the steering stem length. KDX 95-06 triples can be had dirt cheap and will make it a direct bolt in, but you'll need the XR front wheel and XR or 95+ KDX (94+ KX?) brake caliper.

How much do you weigh? If pushing much over 200, I'd say go for a 96+ KX RM YZ CR fork swap for 45mm-48mm forks. They all require steering stem swapping or other work though along with revalving for woods.

Good call, I'll just pick up the front end and if I can't swap in the whole kittenkaboodle then I'll look into a set of 95-06 triples.

[brademan76]

viewtopic.php?f=104&t=25774&p=226963&hi ... 00#p226963

Thx, I had seen this thread and others with plenty of mention of of swapping over the forks but not about the whole front end.

[brademan76]

Have the XR front end. The steering stems are too different. I've not determined if I can press my kdx stem into the XR triples and even if I can what mods I will have to make so the top triple intermfaces correctly as well.

As has been suggested, I think buying a set of kdx triples w/ stem, nuts etc will be simpler. Can I only use a pre-'94 (43mm) set? Or can I use an H-series set?

[Chuck78]

'95-'06 43mm triples are best, as they have better more modern ergonomics with their straight up mounted handlebar risers attached via rubber cone vibration isolator mounts.

'89-'92 are undesirable due to their poor ergonomics on the swept back integrated bar mounts.

'93-'94 KDX200E5/E6 came with lighter fancier but still undesirable spindly thin 41mm tube blue inverted forks, so those triples won't swap whatsoever.

[KDXGarage]

kdxdazz has a video on youtube showing his conversion. Check it out.

1995+ for the clamps.

[brademan76]

kdxdazz has a video on youtube showing his conversion. Check it out.

1995+ for the clamps.

I've seen it. I understand the swap. I guess my question should have been- With my bastard E series USD bike, can I simply swap over other (H-series) triples? I don't know if ther is something different about my frame/neck that would prohibit such a swap.

[brademan76]

'95-'06 43mm triples are best, as they have better more modern ergonomics with their straight up mounted handlebar risers attached via rubber cone vibration isolator mounts.

'89-'92 are undesirable due to their poor ergonomics on the swept back integrated bar mounts.

'93-'94 KDX200E5/E6 came with lighter fancier but still undesirable spindly thin 41mm tube blue inverted forks, so those triples won't swap whatsoever.

Good info, thank you.

[KDXGarage]

The head tube is the same. The newer clamps will work.