KLX Fork Swap Questions

Questions and comments about converting to beefier forks..
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VTMTcowboy
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KLX Fork Swap Questions

Post by VTMTcowboy » 11:18 am Dec 02 2018

Hello fellow KDXers,

I finally pulled the trigger and bought a KLX 300 front end for my 04 KDX. It should arrive next week to fully inspect everything, but regardless I am planning on doing the seals, change out fork oil, and buy new springs with a heavier spring weight. I have never work on forks before and have either two options, do it myself and learn as I go (preferred but dependent on difficulty and tools required), or bring it to a local suspension shop and have them take care of everything. With that being said, is this work something I myself (a novice mechanic) able to do, or should I just suck it up and pay a professional to do it? Also, I will be replacing the races and bearings on the triple clamps and didn't know if I needed a press for those? I found some info on other sites and a couple youtube videos which are a great reference, but I also know there are enough people here that have done the exact same swap. Any help and direction is much appreciated. Thank you!

Ben
1997 KDX 220
2004 KDX 200

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Re: KLX Fork Swap Questions

Post by KDXGarage » 12:02 am Dec 03 2018

On the bearings, do you have a Kawasaki dealer close by? A dealer should have the Kawasaki special tool bearing puller. It pulls the bearing up from the stem. A press is not needed if one has the proper hand tools. There is another special tool that is a tall hollow punch that taps the new bearing down on the stem.

You can use a hammer and punch to slowly drive out the old races. Use something flat to drive in the new races.

I strongly suggest that you remove the old races and install the new races in the KDX. Don't just leave the worn races to use on the new bearings.

Budget for new inner and outer bushings as well.

You may want to think about how long you are OK with spending on doing the work yourself. It won't be simple the first time around.
Thank you Julien D for all your hard work!

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Re: KLX Fork Swap Questions

Post by VTMTcowboy » 11:31 am Dec 03 2018

Yeah I figure it will be a lot of trial and error and questions along the way, but I also will probably get a quote from a suspension shop to see what they would be asking. My be worth it to just pay up. Thanks for the response!
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2004 KDX 200

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Re: KLX Fork Swap Questions

Post by KDXGarage » 11:36 am Dec 03 2018

You're welcome. Good luck with it.
Thank you Julien D for all your hard work!

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Re: KLX Fork Swap Questions

Post by ericr » 12:34 am Dec 04 2018

My experience with races is that you can drift them out quite easily by tapping on the outer edge of the race with a rod or even a long screw driver. When installing the new races, just use the old races to pound them in. But first, use a dremel to cut a slot in the old races. This allows you to get them out after you've driven the new ones lower than flush. I had Ron Black install my lower bearing so I can't help you there. But, I think that finding a piece of tubing along with heating the bearing and cooling the stem should do it.
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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Re: KLX Fork Swap Questions

Post by VTMTcowboy » 11:49 am Dec 04 2018

ericr, thank you sir. Going to weigh all my options once I get all the parts in and once again get a quote from the suspension shop. Would rather do it myself if possible because the knowledge is priceless, but sometimes financials can out weigh things, unfortunately.
1997 KDX 220
2004 KDX 200

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