KLX 450r front end done

[brademan76]

Swapped over forks and triples from 2008 KLX 450r with 48mm KYB AOS forks. Used the Amazon conversion bearing as mentioned several times in the forum. Didn't have to add any shims to get the triples to fit appropriately.

Managed to use the KDX wheel/axle/odometer/brake caliper with a little shimming to center the wheel in the forks and a threaded round nut on caliper side to fit in axle hole, and an appropriately sized bushing for the other side. Still have to work over new brackets to use the KDX front fairing/light and odometer.

Riding around the yard had to drop the front end so forks are up 1/2" above triples for it to feel like front end was in same position as topped out KDX forks. Going for a ride today, hoping to get a feel for if I need to make some shim adjustments.

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[Julien D]

Nice work, looks great! It's a challenge to keep that geometry when doing these swaps. Running them as far up the triples as you can is about all you can do.

[assquatch20]

Curious how it went. Keep us updated. Looks good!

[brademan76]

Was a tough technical trail. A little too much rebound going up the steep shelfy stuff, the front end was wanting to come up too much. I had clickers set 10/22 comp and 12/18 reb. I did go to 8/22 and 10/18 on the way down the trail. Felt a little better.

Definitely need to do some tweeking. Feel like I could soften up base valve, probably will add a crossover shim. Mid speed stuff felt pretty good.
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[Chuck78]

Did they only make that bike for 2 years for the US market? 2008-2009 model years?

That's a great way to get some good off-road KYB forks to swap. I had overlooked that model as I'd almost forgotten entirely about it. Those will likely be very similar to buying some 2004 only Yamaha YZ forks & YZ250 2-stroke triples or first few years of KX250F triples (& '03-'08 KX125/250?), except that these will already be a more suitable valving for woods riding.
Let us know what you find in terms of needing to revolve them or not for the rough terrain.

By the way, I like those shroud graphics with the slightly lighter green infill on the KDX letters, that's a good look with the shade or three lighter green contrasting against the standard 1990's/early '2000's Kawasaki #7F green.