KX Fork Conversion 2019 version

[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!

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!

[rungrandpa]

Looks great.

[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.

[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.

[Kdxfan4130]

Where is the like button?
Nice work

[TwistedRoot]

Thanks everyone. Im really happy with it so far and its now a better bike for me.

[VTMTcowboy]

Looks great! Thanks for the post.

[ericr]

Nice looking bike!

[kdxsully]

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?

[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.

Wow! That’s with stock springs?

That was with .38's up front which is what I currently run on my GasGas EC250.