43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

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Chuck78
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43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by Chuck78 »

Thanks to all the engine & parts specs on http://oem-cycle.com/BikeIdentification.shtml (great eBay used & new parts seller, btw!), I was able to confirm exact dimensions and swap fitment that others had mentioned here in the past, & realized this could really help KDX fork swappers looking to run 91-95 KX125/250 forks.

The 91 KX125/250 triple clamps will swap to the KDX frames, but 92-95 KX125/250 triples will require a stem swap, although those years stem swap may be the exact same press fit diameter as the KDX stem (most '96+ upgrade forks use a steering stem several thousandths of an inch larger, making the KDX stem no longer a press fit, and requiring knurling to increase the o.d. slightly on the stem, + retaining compound.

It's also pretty well stated all over the forum that KLX250/300/650 triples through at least 2007 should all be the same clamping diameters as 91-95 KX125/250/500 forks, and I believe from references on this forum, that 91-94 KDX250 triple clamps share these same dimensions. Most KDX250's (exact same triple clamp as the KLX650R) use a lighter aluminum steering stem also, for a minor weight savings 👍

So the KLX or KDX250 triples can mount the 91-95 KX125/250/500 forks as a direct bolt-on, and 94-95 are mid valve forks, a bit more advanced progressive damping that helps for higher speed riding and racing, and also have a 20mm axle and bearing size, which increased tracking and flex resistance. The bearing and axle may have jumped to 20mm in 93, but there are conflicting sources on the internet.

You'll of course need the KX front wheel as well, as it has a larger diameter 17mm axle or 20mm axle (depending on year) which will give you another advantage over the 43mm KLX forks & the stock KDX/KLX 15mm axle in terms of front end rigidity, as well as the external adjustable rebound and compression of KX forks vs KDX/KLX, + the 94-95 having additional compression stacks on the mid valve, for more progressive high speed damping vs previous years with only base valve compression stacks (perfectly fine for casual woods roding, but mid valves help out in hard fast racing use, desert riding, and motocross).

The KX500 triples these years will be a direct bolt-on to the KDX, but 91-95 / 96 / 97-04 KX500 forks and triples are scarce to come by...

94+ ('93+ perhaps???) KX125/250 use a 20mm front axle, so the wheels must come from 90(?) or 93/94-98, unless you have the '91-'92 forks ('91-'93???) which use the 17mm axle, then you need I believe the '90-'92 ('90-'93?) wheel?

I hope this helps someone! No stem swap required when going this route!



EDIT - I feel the need to add here that you should look up the exact model and year on the Race Tech Product Search to see what original spring rate came in these forks you're buying, as the aftermarket options for the 43mm forks are very slim. The stock springs were in the .38kg/mm-.40kg/mm range, which is great for a 145-175lb woods rider. These forks are not substantial enough to support a 195lb aggressive woods rider/racer however, so I wouldn't really consider them if you are heavier (there is one heavier spring rate available from Race Tech, but you should measure the springs and ask Cannon Racecraft if they have one that will fit them or browse their catalog for that year make model. They may not list back that far, but may in fact have something to fit.
Also, the forks are likely to have the original springs in them still, but also, that's just not guaranteed if it has been resprung sometime in it's 30 year lifespan...
Last edited by Chuck78 on 02:11 pm Feb 16 2025, edited 1 time in total.
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by KDXGarage »

1991 offset is different than 1992 - 1995 KX125 / KX250. No mix and match on upper and lower clamps.
Thank you for participating on kdxrider.net. :bravo:
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by Chuck78 »

I also believe that 1996 KX500 triple clamps are completely different, & a quick check on Partzilla shows the KX500 lower triple clamp being unique to that year, so at minimum I'd suspect the offset to be different, making it a 96-only upper & lower compatibility.

OEM-Cycle.com 's specs show clamping diameters of every other year before and after, but not '96 KX500, so I'd be cautious to only use a matching pair of triples and fork if finding a 43mm '96 KX500 front end. I don't see why they'd use a different upper tube on a '96, after all, 500cc open class bikes were no longer a competition sanctioned model, and therefore they no longer were getting the cutting edge development that the 125 & 250 2-stroke were. Still, I cannot yet verify clamping diameters.

If anyone could verify the '91-'94 KDX 250 clamping diameters for certain, that would be excellent.
'97 KDX220R - purple/green! - KLX forks, Lectron, FMF, Tubliss
'99 KDX220R project - '98/'01 RM125 suspension, Titanium hardware, Lectron Billetron Pro, Tubliss
'77 Suzuki PE250 & '83 Suzuki PE175 Full Floater - restomod projects
'77 Suzuki GS750-844cc, '77 GS400/489cc & '77 GS550/740cc projects
'62 GMC 1000 Panel Truck
'88 Suzuki Samurai TDI/Toyota swaps
'88 Toyota 4x4 pickup
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by Chuck78 »

I've got some other more modern fork swap tips and links to share as well, 2011-2016+ Showa Twin Chamber SFF 47mm & 48mm forks, but I'll make a separate topic for this. It's quite spendy, but no machining is required with KX Guru Racing billet triple clamps and steering stem...
'97 KDX220R - purple/green! - KLX forks, Lectron, FMF, Tubliss
'99 KDX220R project - '98/'01 RM125 suspension, Titanium hardware, Lectron Billetron Pro, Tubliss
'77 Suzuki PE250 & '83 Suzuki PE175 Full Floater - restomod projects
'77 Suzuki GS750-844cc, '77 GS400/489cc & '77 GS550/740cc projects
'62 GMC 1000 Panel Truck
'88 Suzuki Samurai TDI/Toyota swaps
'88 Toyota 4x4 pickup
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by brademan76 »

Chuck78 wrote: 03:08 pm Nov 29 2023 ...
You'll of course need the KX front wheel as well, as it has a larger diameter 17mm axle which will give you another advantage over the 43mm KLX forks & the stock KDX/KLX 15mm axle in terms of front end rigidity, as well as the external adjustable rebound and compression of KX forks vs KDX/KLX, + the 94-95 having additional compression stacks on the mid valve, for more progressive high speed damping vs previous years with only base valve compression stacks (perfectly fine for casual woods roding, but mid valves help out in hard fast racing use, desert riding, and motocross).

96+ KX125/250 use a 20mm front axle, so wheels must come from 90(?) or 91-95.

I hope this helps someone! No stem swap required when going this route!
As you recommended, I'm looking at 94-95 KX forks. Looks like the front wheel/axle changed to the 20mm starting in '94.
https://www.oem-cycle.com/forum/viewtopic.php?t=186

I'm sure it's mentioned elsewhere but does a KDX caliper fit on the KX forks/rotor or would a person need get one of those from a KX as well?
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by Chopperpilot »

The KDX caliper did NOT fit on my 93 KX250 fork legs (installed with KLX650R triple clamps). I keep hearing about the 17mm axle.... but the wheel and axle I got, that fit in the fork legs, is a 20mm (these were a separate ebay purchase though). I 'think' 94 and up used the same caliper, I know my 96 KLX650R has the same front caliper as the KDX (same mounting anyway and brake pads anyway).
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Re: 43mm '91-'95 KX fork swaps made easier - KLX / KDX250 triples

Post by brademan76 »

Good to know 👍
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