KX Fork Conversion / Required Knurling?

[Bigdavelittle]

I have just had a 2006 KDX stem pressed into a 2002 KX lower clamp, no knurling required. Pressed in nicely.
The KDX stem was very tight to remove from the KDX lower clamp, the KX stem came out way easyer.

[SACTO_STEVE]

I JUST DID A KX SWAP THE FRONTEND WAS FROM A '96 KX250 ALL THAT WAS REQUIERED WAS TO SWAP STEMS AND TO MACHINE TWO SPACERS (ONE FOR THE PRELOAD ADJUSTER AND ONE FOR THE TOP STEERING NUT) DO TO THE LENGTH OF THE KDX STEM IN THE KX TREES

[ITracerMike]

I just installed a 2001 KDX stem into 2004 KX250 clamps with no press required. We use liquid nitrogen for chilling large shafts at my work so while a tech was chilling a shaft this morning I placed my stem into the container of liquid nitrogen long enough for me to warm the bottom clamp to approx. 180f . I was able to slip the stem into the lower clamp with virtually no resistance and held it long enough for the clamp to cool to an interference fit. For those without access to a press you may be able to get the same results by freezing the steering stem ( leave in deep freezer overnight) and heating the lower clamp just as I did . note: all parts were measured beforehand to confirm an interference fit upon assembly.

[GATOROC]

Thought I'd add my experience on here as well. I picked up a complete 1997 KX250 front end, and after pressing out the KDX/KX stems and putting the KDX stem in the KX lower clamp, it had very little resistance and could be pressed in buy hand. I finally found a shop to do the required knurling and then it was able to be pressed in properly.

[rampeyboy]

1999 KDX200. Used 1994 KX250 front. Did not need to knurl bottom clamp. Did require press to remove and install stem. Used .020 aluminum around top of stem for "bushing" where top clamp fits. Worked perfect. My bars are 7/8 so had to swap the bar mount from KDX to KX top clamp. Only thing left now is to secure the brake line to the fork shield and put KX rim on front and ride!