2003 KDX220R Fork Conversion Questions

[gumbo583]

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.

[KDXGarage]

Welcome to kdxrider.net.

If you want to ride MX without buying a MX bike, then MX forks are the ones to be looking for. I would suggest a set of KX forks, clamps, etc. Price and condition vary greatly. Be aware that almost all USD forks will have the clamps hitting the sides of the fuel tank on a 1995+ KDX. Even 43 mm inner tubed USD forks will cause a slight hit. Some have modified the steering stops to limit the amount of left to right swivel of the clamps. There are a lot of threads in our "Fork Conversion" subforum.

Good luck.

[SS109]

Prices anywhere from $300 and up. Easiest is a set of later model KX500 forks as they are a straight bolt on but they are hard to find. Otherwise pick your fork setup, swap stems, get RB's stem adapter bushing, and bolt it on.

I agree with everything KDXGarage said.

Any modern (last 20 years or so) USD forks should work well. I would personally stay away from any air fork or single function (SFF) fork due to the unique issues those forks can have, and the expenses associated with them, but that's just me. I would also stick with common forks like KYB or Showa mainly due to cost and availability. Forks like WP, Marzocchi, and Ohlins can be great (love my 'Zoke 48 PFP's on my GasGas!) but finding parts, good suspension tuners, and costs can be a pain at times.

I tend to stick with forks from a KX series bike as things tend to be easier due to brake caliper mounts and such. I have used forks from a '98 KX125 (46mm KYB) and my current KDX has forks from an '05 KX250F (48mm Showa). Both were/are awesome setups. Both sets just barely touch/touched my fuel tank but I never felt the need to modify the steering stops.

Just try to find a complete front end to make it the easiest swap over. Clamps, forks, wheel, axle, bar mounts, and possibly brake caliper/mount, brake line, and master cylinder.

[Slick_Nick]

Welcome to kdxrider.net.

If you want to ride MX without buying a MX bike, then MX forks are the ones to be looking for. I would suggest a set of KX forks, clamps, etc. Price and condition vary greatly. Be aware that almost all USD forks will have the clamps hitting the sides of the fuel tank on a 1995+ KDX. Even 43 mm inner tubed USD forks will cause a slight hit. Some have modified the steering stops to limit the amount of left to right swivel of the clamps. There are a lot of threads in our "Fork Conversion" subforum.

Good luck.

I used 43mm KYB's off a '95 KX125 and the steering stops needed no modification. Just had to machine the top hat spacer and knurl my stem. Details in my rebuild thread.

[Slick_Nick]

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.

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.

[gumbo583]

Thank you everyone for so much advice. I think I will choose the KLX300 forks. What year would be the easiest "bolt-on" fit?

[doakley]

Don’t let the perceived complexity of converting to true MX forks scare you into using lesser forks. It really isn’t that difficult.

[Slick_Nick]

Thank you everyone for so much advice. I think I will choose the KLX300 forks. What year would be the easiest "bolt-on" fit?

Any year. Be warned they will hit your tank.

[gumbo583]

Is it a bad thing that the forks will be hitting my tank? Can i put like rubber on the tank where the forks hit? Thank you so much for the help.

[Slick_Nick]

Is it a bad thing that the forks will be hitting my tank? Can i put like rubber on the tank where the forks hit? Thank you so much for the help.

They can crack your tank if you fall. What good would rubber do? It'll just make the forks push harder on the tank. You can have your steering stop modified so they don't hit, easy enough to do if you're a competent welder.

[doakley]

I drilled the lower clamp and put in an aluminum screw. The thickness of the screw head was just enough to keep the forks off my tank. Problem solved.

[gumbo583]

Is it a bad thing that the forks will be hitting my tank? Can i put like rubber on the tank where the forks hit? Thank you so much for the help.

They can crack your tank if you fall. What good would rubber do? It'll just make the forks push harder on the tank. You can have your steering stop modified so they don't hit, easy enough to do if you're a competent welder.

Do you think 2009 KLX250 forks with triple clamps will fit like a KLX300 triple clamp?

[Molly's 70]

I used my TIG welder to build up some material on the triple clamp, then smooth it down so you can't even notice.

[gumbo583]

I was going to replace my stock KDX forks with KLX300 forks, but they are not very common. KX forks seem to be more abundant, so I was wondering what fork/triple clamp from the KX series of dirt bikes would be the best? I know that that from 1995 to 2006, the KDX220R and KDX200 have been basically the same but I just want to make sure, just give me a range of what year of KX forks will fit my frame. Thank you!!!!!!

[gumbo583]

Prices anywhere from $300 and up. Easiest is a set of later model KX500 forks as they are a straight bolt on but they are hard to find. Otherwise pick your fork setup, swap stems, get RB's stem adapter bushing, and bolt it on.

I agree with everything KDXGarage said.

Any modern (last 20 years or so) USD forks should work well. I would personally stay away from any air fork or single function (SFF) fork due to the unique issues those forks can have, and the expenses associated with them, but that's just me. I would also stick with common forks like KYB or Showa mainly due to cost and availability. Forks like WP, Marzocchi, and Ohlins can be great (love my 'Zoke 48 PFP's on my GasGas!) but finding parts, good suspension tuners, and costs can be a pain at times.

I tend to stick with forks from a KX series bike as things tend to be easier due to brake caliper mounts and such. I have used forks from a '98 KX125 (46mm KYB) and my current KDX has forks from an '05 KX250F (48mm Showa). Both were/are awesome setups. Both sets just barely touch/touched my fuel tank but I never felt the need to modify the steering stops.

Just try to find a complete front end to make it the easiest swap over. Clamps, forks, wheel, axle, bar mounts, and possibly brake caliper/mount, brake line, and master cylinder.

I found a pair of 1993 kx500 forks, is that gonna fit the 2003 kdx220r?

[doakley]

I’m wondering what the technology difference is between 1993 forks and something newer? I’d still look for some early 2000,s KS 250/125 forks or perhaps even newer 250KXF forks. Of course this depends on if you are just looking for an MX look or if you’re trying to make the most performance improvement.
Remember just slapping on more updated forks is a big improvement but you’ll still want to tune the (and the shock too) to match your weight, skill level (speed) and intended use, Enduro, MX or HS. Good luck with the change!

[KDXGarage]

Bro, the "Fork Conversion" subforum has been around for 16.5 years. You may be able to just read old threads and learn for days. :-)

[KDXGarage]

gumbo, yes

Just be aware that they are 30 years old. same as 1991 forks.

doakley:

midvalve came in 1995 to 125 / 250
1993 KX500 forks are the same as 1991 KX500 forks.
Later forks had bladders or bumpers, depending on the year.

Any 46 mm inner tubed forks will tap the tank. 48 mm will be even worse.

[Slick_Nick]

Yeah they'll work, but they're not gonna be much better for your bike.

[gumbo583]

Bro, the "Fork Conversion" subforum has been around for 16.5 years. You may be able to just read old threads and learn for days. :-)

Why do you think I am asking this question then? Dont you think I would have done reseaech before hand? I am just wondering which kx forks would fit best for my model and year. I get constant attitude for not having the necessary knowledge on what to look for.