2003 KDX220R Fork Conversion Questions

Questions and comments about converting to beefier forks..
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3455
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA

Re: Best KX Fork for 2003 KDX220R??

Post by bufftester »

The KLX fork swap is easy because you don't have to do much more than bolt it on. But the forks aren't any more advanced than the stock ones (just USD instead of conventional). KX500 front ends are also a straight swap, but harder to come by. Right now, perusing through Ebay it looks like you can pick up 02-05 kx125/250 forks and triples fairly cheap. You do have to swap the stem between triples and do some work with steering stops, but you end up with a much more adjustable fork setup. Other than the 2 mentioned above, there are no direct swap front ends.
Keep in mind any KX fork is going to be valved wrong for woods riding, so that is extra work/time/money that needs to be considered. I have 02 KX250 forks on my hybrid, and revalved them myself and they work great. You could probably find some even later (2015 and up) KX-F forks, just have to figure out the steering stem swap. Lots of good info in the fork swap section.
Honestly, if you get the proper springs for your riding weight and upgrade to Gold Valves, the stock forks work just fine, and are good for nearly everything just this side of Supercross. And at $200-300 depending on what deals you can find, you can upgrade both the front and rear. Best money you will ever spend on your bike. Just because they aren't USDs doesn't mean they need to be replaced.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: Best KX Fork for 2003 KDX220R??

Post by KDXGarage »

You already had one thread about forks. Please continue on in that thread instead of starting a new thread. Sorry if you thought I was giving you attitude. People have already been replying to you. I merged your second thread to this thread.

KLX250 (old models) or KLX300R are easiest, followed by KX500 / 1991 KX125 / 1991 KX250

Beyond those, one has to do a stem swap. You want easy, look above.

EDIT: This post was moved from a second thread.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by SS109 »

Any fork conversion done on any '95 and up KDX applies to your bike. So, look at what people have used on any of those bikes and you'll see what they had to do to fit them.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by Slick_Nick »

I think the issue you're running into is that you only want the LOOK of modern forks, and you don't seem to be considering much how it's going to affect the geometry and handling of your bike. Throwing on the most modern forks you can, say off a newer KXF, will leave your bike "choppered out" with the front end super high, and no room to move the forks up in the clamps without hitting the bars. Not to mention it'll handle like ****.
'00 KDX 220R
gumbo583
Member
Posts: 22
Joined: 07:59 pm Jul 03 2021
Country: United States

Re: 2003 KDX220R Fork Conversion Questions

Post by gumbo583 »

Slick_Nick wrote: 09:23 am Jul 04 2021
gumbo583 wrote: 12:04 am Jul 04 2021 I have a 2003 KDX220R, what is the easiest route to get inverted forks? I am converting my bike into a more mx style machine. I already have it looking like one cosmetically, except for the forks. I just want to know a general idea of the price and which forks/triple clamps would be the easiest to bolt onto the frame. :grin:
As far as the easiest, cheapest, no-modification route, you're looking at KX500 or KLX300 forks. The KLX will work with your stock front wheel, brake, and speedo. Modern fork guards can be made to fit easily for a better look.

The forks still suck, but sounds like you're just after making it LOOK like an MX bike, so they'll do the job.
Wondering if 1995 KX500 forks will fit my breaks, axel, ect. I have a 2003 KDX220R.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by KDXGarage »

Did you look up the wheel bearing inner diameters?
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by Slick_Nick »

gumbo583 wrote: 08:50 pm Aug 05 2021
Slick_Nick wrote: 09:23 am Jul 04 2021
gumbo583 wrote: 12:04 am Jul 04 2021 I have a 2003 KDX220R, what is the easiest route to get inverted forks? I am converting my bike into a more mx style machine. I already have it looking like one cosmetically, except for the forks. I just want to know a general idea of the price and which forks/triple clamps would be the easiest to bolt onto the frame. :grin:
As far as the easiest, cheapest, no-modification route, you're looking at KX500 or KLX300 forks. The KLX will work with your stock front wheel, brake, and speedo. Modern fork guards can be made to fit easily for a better look.

The forks still suck, but sounds like you're just after making it LOOK like an MX bike, so they'll do the job.
Wondering if 1995 KX500 forks will fit my breaks, axel, ect. I have a 2003 KDX220R.
A lot of what you're asking you can figure out yourself with some research. Go on Kawasaki's site and start pulling up parts diagrams. Compare the numbers of the stuff you want to swap over, you'll see that a lot of them are the same.
'00 KDX 220R
Offroadguy
Member
Posts: 3
Joined: 03:42 pm Aug 28 2022
Country: United States
Location: Folsom CA

Re: 2003 KDX220R Fork Conversion Questions

Post by Offroadguy »

[album][/album]

Hi I used 98 KLX 300 forks and clamps on my 2000 KDX 200 with racetech .42 springs and their valving. I used my kDX wheel and Caliper which was a direct bolt up.
I Love the setup. But HATED the KLX guards!

KLX fork guards are terrible so I ordered these black Acerbis for a 1994 KX. I run them with no keepers. I trimmed them a little and ground the stock KDX brake cable bracket smooth on the back. Drilled two holes in the fork guard and mounted it with two pan head 6 mm screws. Sturdy, clean and cheap!

Big difference in performance and looks
Attachments
Klx300 fork swap  Acerbis 94 kx guard
Klx300 fork swap Acerbis 94 kx guard
F6AB78C3-61F8-42CA-AA89-FA88CAE1D172.jpeg (3.36 MiB) Viewed 2256 times
Kx guard on klx forks
Kx guard on klx forks
027A549F-9C26-47F1-BA66-BBCE32B16661.jpeg (3.36 MiB) Viewed 2256 times
2CF1AD85-5CEB-44AB-BBCF-4D8CE004B762.jpeg
2CF1AD85-5CEB-44AB-BBCF-4D8CE004B762.jpeg (3.53 MiB) Viewed 2256 times
70424B9F-A716-429E-B4D1-796FE26BC208.jpeg
70424B9F-A716-429E-B4D1-796FE26BC208.jpeg (3.22 MiB) Viewed 2256 times
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by Slick_Nick »

Those screws are going to destroy your fork tubes every time the forks compress. Try a set of newer fork guards from something that have a built in support for the brake line clamp.
'00 KDX 220R
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: 2003 KDX220R Fork Conversion Questions

Post by KDXGarage »

Yep, without fork guard guides, it is going to get destroyed quickly.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Post Reply