Finally Doing Swap to 1997 KX250 Forks

[GATOROC]

I had thought about the MX rear fender and number plate since I never ride at night anyway. It is nice to have it just in case you ever do. I like the MX look.

Yeah, so far I haven't had to ride at night. When I first got the bike I was set on keeping the lights, doing the stator rewrap, etc., but as time has gone on I've decided to make the bike more modern looking. In the future I may go back to a front light and DRC tail light for the Maier fender, but for now I'll just carry a headlamp in my backpack in case I get stuck riding at night. Here's a few pics of the new look:

Maier Rear Fender, on Flickr

Maier Rear Fender, on Flickr

[javjacob]

3 KDX's and a 70-72 chevy... that's a lot of good taste all in 1 pic.

[GATOROC]

He’s retired.

Just an update on RB Designs - I've been emailing back and forth with Ron and I asked if he could clarify what his status is due to the different messages we're getting from different folks. Here is his response below, and I will post this in the RB Designs section as well.

"As for what I’m up to, well I am slowing way down, but still doing KDX work. I am only selling brand new carbs with my mods already done (99% of the stock carbs are worn out and need too many parts and time to replace anyway).

I do the stock 220 head mods (no longer doing the 200 heads). I do accept machine work, at my choosing on what I will do.

I have gone into a semi retirement, but still doing work of my choosing and at my pace as I love doing what I do for the KDX 200/220..., but I’m getting older and need to stop and smell the roses so to speak and spend time with family and myself. So if you are in a rush or have strict time restraints I’m not interested in the work, but if I can do it on my time line and not in a big hurry it’s a go....

Ron"

[GATOROC]

3 KDX's and a 70-72 chevy... that's a lot of good taste all in 1 pic.

Haha! Some classics right there! You should see his other C10 lowrider show truck.

[javjacob]

Thanks for clarifying RB Designs status. I always round up the money I send him. His work is worth more than he charges anyway.

[kdxsully]

3 KDX's and a 70-72 chevy... that's a lot of good taste all in 1 pic.

Haha! Some classics right there! You should see his other C10 lowrider show truck.

I have an unexplainable love for old trucks. One day I want to pick myself up an F100.

[KDXGarage]

Thanks for the info!

Nice looking bikes!

[Goat]

Thanks Gator! I don’t see any $150 complete front ends handy in my local.
But seems a good idea to get the front end swapped while RB is still there to help make it easy.

[Goat]

RB must be recharged. He answered in 1-day that he’d be happy to do a stem swap for me, also.
So now I gotta go shopping.
Luckily my wife is up on latest etiquette trends and found that 32-yrs = The KX125 Front End Anniversary

PS. I agree that truck is pretty sweet, but I am jealous of your kickstand. KDXG has mentioned a mythical place where expansion chambers aren’t dented, and now this dogleg free support system turns up! The Colorado Springs must have a little magic.

[GATOROC]

Luckily my wife is up on latest etiquette trends and found that 32-yrs = The KX125 Front End Anniversary

PS. I agree that truck is pretty sweet, but I am jealous of your kickstand. KDXG has mentioned a mythical place where expansion chambers aren’t dented, and now this dogleg free support system turns up! The Colorado Springs must have a little magic.

Haha! Glad that your wifey concurs with the front end swap! I wonder how many KDX owners have just taken off their kickstand and thrown it in the garbage, not knowing that it is on par with the value of gold?

[KDXGarage]

HA HA!!

[GATOROC]

Well, I picked up my forks from Pro-Action Suspension the other day, but when they pressed out the stems from the KDX and KX and went to press the KDX stem in the KX triple clamp, it just fell right in with no resistance. I thought that finding someone to knurl the stem would be easy, but it took calling/going to 4 different places before I could find someone to do it. Got the stem pressed into the triple and bearing pressed on as well. The bearing went all the way down, so that was nice.

I'm waiting on some parts (master cylinder rebuild kit, pads, fender, front plate, lower shock guards, etc.) to show up today and will work on getting the front end assembled. Here are a few pics so far:

Pro-Action Suspension Forks, on Flickr

KDX Stem in KX Lower Triple Clamp, on Flickr

Fork Bleeders, on Flickr

RB Designs Stem Shim-Spacer 1, on Flickr

RB Designs Stem Shim-Spacer 2, on Flickr

[KDXGarage]

LOOKS GOOD!

Are you certain the clamps are from 1997? Any chance they are 1996? How much gap was there?

Are you certain your KDX clamps are from 2000?

That sounds odd from what I remember from YEARS ago.

[SS109]

Awesome! Get that baby done and get riding!

[G22inSC]

Did you have the KX forks internally shortened? If not, the fork bleeder may be blocked by your handlebars depending on how far you raise the forks in the tree.

[GATOROC]

LOOKS GOOD!

Are you certain the clamps are from 1997? Any chance they are 1996? How much gap was there?

Are you certain your KDX clamps are from 2000?

That sounds odd from what I remember from YEARS ago.

I'm not 100% positive that the clamps are '97, but the guy I bought the whole front end from is knowledgeable about bikes and he advertised the complete bike as a '97. I don't see any reason he wouldn't list the correct year of bike, but it is possible. Also, I'm not 100% sure that the KDX clamps are 2000, but the bike was pretty much stock when I bought it.

There wasn't really any gap with the stem, but just enough to slide through where it didn't need to be pressed. A little knurling solved the issue. During my research on the forum there's a thread (link below) about whether knurling is required or not, and it seems that it's hit and miss with certain years. You mentioned above about the clamps possibly being from '96. I have no idea about the different years, but from this thread KX Fork Conversion/Required Knurling? KDX220PHIL says:

KX250, Post 1990, that share identical part numbers for lower clamp assembly:

98-00 - 44037-1371
96-97 - 44037-1338
92-94 - 44037-1298
All other years up to and including 06 have different part numbers, this does not mean they do not share the same stem measurements.

[GATOROC]

Did you have the KX forks internally shortened? If not, the fork bleeder may be blocked by your handlebars depending on how far you raise the forks in the tree.

I did not have the forks shortened internally, but probably should have done that. Another option is to run some bar risers. I took measurements before disassembling the front end, so I will compare measurements after putting on the KX forks to see how much difference there is. If I have to get rid of the bleeders, no biggie since it's just a convenience.

[SS109]

IIRC, when I installed my '96 KX125 front end the stem from my '90 KDX didn't require knurling.

As for shortening the forks internally, I didn't do it on either of my front end conversions ('90 KDX/'96 KX125 forks or '98 KDX/'06 KX250F forks) and I could/can reach the bleeders and clickers on both.

[KDXGarage]

I have a set of what are supposedly 1996 clamps. The stem OD is bigger than the other clamps is why I asked.

[GATOROC]

Got some time yesterday to get things back together. I was able to get the fork tubes about 1/2" up into the triple clamp and still have about 1/4" of space between the bars and bleeders. I haven't measured to compare the height between the old and new forks, but I can tell that the bike sits a little bit higher now. I still need to get the Shinko Fatty Tyre switched out with the little tire that's on there now, and will get the Tubliss swapped over to the new rim as well. The weather has been really cold here with snow as well, so I haven't had an opportunity to ride it yet. A few pics of the new setup:

1997 KX250 Front End 11, on Flickr

1997 KX250 Front End 14, on Flickr

1997 KX250 Front End 12, on Flickr

1997 KX250 Front End 13, on Flickr

1997 KX250 Front End 15, on Flickr