KX Fork Conversion 2019 version

Questions and comments about converting to beefier forks..
Post Reply
User avatar
TwistedRoot
Gold Member
Gold Member
Posts: 323
Joined: 02:56 pm Oct 08 2017
Country: United States
Location: Florida, US

KX Fork Conversion 2019 version

Post by TwistedRoot »

I recently did the KX (’99) fork conversion on my ’02 KDX200. I wasn’t actively looking to do it but after some riding in the gnarly stuff I had to. The stock fork action was fine for trails but I had a few scary moments with the flex and ruts so I pulled the trigger. I know this is nothing new, its been discussed a million times here but I, (like everyone else) encourage anyone with a KDX to do this if your a bigger than average rider, or if you just hammer hard on the stock fork. I have about 5 hours on it since the swap. Much more solid feel but no “plushness”. They will need some tweaking for the junk I ride. But the seals don’t leak and the oil looks pretty clean. I will be looking into the shim mods but Im ok with them for now. I also picked up a Pivot Works kit (seals, wipers, bushings) on fl-ebay for $55 to do the job.

I decided to go with RB for the KX stem swap and KDX axle mod. I think he’s been doing these mods over 10 years. Quick turnaround (only 6 days with a weekend in between) and well packaged. Great experience overall. Im stoked.

My KDX wheel, rotor, Millville II tire, and Endurance II speedo are all in like-new condition so I planned on using them from the start.
I run Fat bars w/ProTaper mounts and went with the KX250 upper tree which has holes (125 upper tree is cast). I think the forks are up around 24mm in the clamps now. The KX250 forks also have the stiffer springs, (.43kg?) which I wanted. I will prob have to seek out the "entity", (oracle?) to dial them in! :lol: :mrgreen: :shh:

I still have a few things to do like the speedo routing. After reading a lot of other posts, (thanks eric_r!) I think I will rivet an aluminum bracket onto the guard to stabilize the lower cable. The total down time was about 10 days. Super easy job. I wasn’t sure I could do it, but this site and its great posts showed me the way. I took a lot of pics and wanted to post them since I think we lost some after the update. Hope you guys like them. THANK YOU KDXRIDER.NET! :bravo:
Attachments
IMG_1374w.jpg
IMG_1374w.jpg (492.25 KiB) Viewed 4219 times
IMG_1A3w.jpg
IMG_1A3w.jpg (517.12 KiB) Viewed 4219 times
2002 KDX 200
2003 KDX 220
User avatar
rungrandpa
Supporting Member I
Supporting Member I
Posts: 230
Joined: 11:35 pm May 26 2018
Country: U.S.A.

Re: KX Fork Conversion 2019 version

Post by rungrandpa »

Looks great.
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: KX Fork Conversion 2019 version

Post by KDXGarage »

Yeah it does! Congratulations!

If you have the stock valving, then definitely do the o-ring to spring conversion and lighten up the base valve for sure.

Entity out. :mrgreen:
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: KX Fork Conversion 2019 version

Post by SS109 »

Awesome! Get those forks revalved and you'll really start to see all the benefits of a more modern front end. On both my KDX's, my '90 and my '98 220, it was worth every penny! Yeah, I wondered how good a front end conversion could be until I started becoming a faster rider and noticed the forks flexing. That flex almost got me seriously hurt on many occasions, and I'm only 140lbs, and anything over about 15mph it could send me off trail without warning.
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
Kdxfan4130
Supporting Member II
Supporting Member II
Posts: 116
Joined: 09:24 pm May 30 2019
Country: Usa

Re: KX Fork Conversion 2019 version

Post by Kdxfan4130 »

Where is the like button?
Nice work
Restore rather than replace
User avatar
TwistedRoot
Gold Member
Gold Member
Posts: 323
Joined: 02:56 pm Oct 08 2017
Country: United States
Location: Florida, US

Re: KX Fork Conversion 2019 version

Post by TwistedRoot »

Thanks everyone. Im really happy with it so far and its now a better bike for me.
2002 KDX 200
2003 KDX 220
User avatar
VTMTcowboy
Gold Member
Gold Member
Posts: 580
Joined: 07:50 pm May 26 2017
Country: USA

Re: KX Fork Conversion 2019 version

Post by VTMTcowboy »

Looks great! Thanks for the post.
1997 KDX 220
2004 KDX 200
User avatar
ericr
Gold Member
Gold Member
Posts: 246
Joined: 06:57 pm Nov 06 2017
Country: USA
Location: Gig Harbor, WA

Re: KX Fork Conversion 2019 version

Post by ericr »

Nice looking bike!
'02 KDX 200, '02 KDX 220 - My restoration thread
kdxsully
Supporting Member
Posts: 739
Joined: 08:28 am Apr 21 2019
Country: United States
Location: North Cackalack

Re: KX Fork Conversion 2019 version

Post by kdxsully »

SS109 wrote: 01:03 pm Jul 03 2019 Awesome! Get those forks revalved and you'll really start to see all the benefits of a more modern front end. On both my KDX's, my '90 and my '98 220, it was worth every penny! Yeah, I wondered how good a front end conversion could be until I started becoming a faster rider and noticed the forks flexing. That flex almost got me seriously hurt on many occasions, and I'm only 140lbs, and anything over about 15mph it could send me off trail without warning.
Wow! That’s with stock springs?
I like turtles
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: KX Fork Conversion 2019 version

Post by SS109 »

kdxsully wrote: 10:01 am Jul 04 2019
SS109 wrote: 01:03 pm Jul 03 2019 Awesome! Get those forks revalved and you'll really start to see all the benefits of a more modern front end. On both my KDX's, my '90 and my '98 220, it was worth every penny! Yeah, I wondered how good a front end conversion could be until I started becoming a faster rider and noticed the forks flexing. That flex almost got me seriously hurt on many occasions, and I'm only 140lbs, and anything over about 15mph it could send me off trail without warning.
Wow! That’s with stock springs?
That was with .38's up front which is what I currently run on my GasGas EC250.
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
Post Reply