if you want to save money, you can use the dimension above to fab your own axle using the stock kdx axle. it is applicable to E and H series kdx 200 or 220. You need to fab your own spacer on the brake side to 15mm(corrected from drawing 14mm) width. no spacer need on the right side. material used will be 4340 or 4130 steel.
this is my completed KX fork conversion using 2005 KX125 fork on my E series KDX200
Ron Black did my shim spacer for the triple tree. he done a great job for just $20. Shim spacer to fit under top triple clamp.
this is a way i found on this site for the steering head stopper mod to stop the kx fork from hitting the tank. nice job.
Summary :
1) E series steering head is the same as H series steering head. they share the same top and bottom bearing.
2) 2005 KX125 fork do not require knuarling for either H series KDX 200 or 220, prefect fit. just press out the stock KX stem out from the threaded side down, then press in the stock KDX stem from bottom into the KX triple using a press.
3) note that you cant have the bottom steering head bearing all the way seated after you have pressed the kdx stem onto the kx triple. it will have about 3mm of gap below. this is normal. no action needed.
4) using 2005 above KX125 fork will also solve the brake line routing issue. you can use the stock kdx line and caliper to the kx fork. perfect fit.
5) you can also use KX250F fork guard, they are compatible to 2005KX125 onwards.
6) kx125 top clamp torque is 19Nm
bottom clamp is 11Nm
steering head stem nut is 44Nm
axle pinch bolt is 20Nm
front axle is 78Nm
7) I am using kx250F front fender on my kx125 triple. perfect fit.
8) I am using UFO front headlight rubber straps top and bottom on my stock KDX headlight. perfect fit.
9) I weight 65kg with no load.
put in DSP 0.38kg/mm fork spring
fork oil 5wt
oil height 120mm (adustable range is 90mm to 140mm)
stock shim stack
