Upper Triple Clamp Swap for KDX H series
Upper Triple Clamp Swap for KDX H series
I am doing a usd fork swap on a 2003 KDX200. I have the complete fork setup from a 2001 KLX300. I put 1 1/8 bars on the stock forks. I am looking for a upper clamp that I can swap out the KLX300 7/8 bar mounts for 1 1/8 bar mounts. Will any other stock upper clamp bolt directly to the KLX stem so I can use my 1 1/8 bars? I am using a BRP Pro SX 1 1/8 bar mount. Hope this all makes sense. Thanks for any help.
- KDXGarage
- KDXRider.net

- Posts: 14741
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Has thanked: 181 times
- Been thanked: 46 times
- Contact:
Re: Upper Triple Clamp Swap for KDX H series
CHECK THE OFFSET, but 1991 - 1994 KDX250 may work. Also, 1991 KX250 and 1991 - 1993 KX500.
I can not remember the offsets.
I can not remember the offsets.
Thank you for participating on kdxrider.net. 
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
- Chuck78
- Gold Member

- Posts: 1551
- Joined: 06:20 pm Nov 30 2016
- Country: USA
- Location: Columbus, OH
- Has thanked: 290 times
- Been thanked: 139 times
Re: Upper Triple Clamp Swap for KDX H series
I have a KX250 (1995?) upper triple clamp that I'd gotten specifically for this reason, but I'd just kept running the stock KLX300 solid upper triple with bar riser fatbar adapters.
I can check to see if there are any identifying marks on it, there may be the last 4 digits or so of the Kawasaki part # cast into it in typical fashion.
I do know that 1991 KX triples have a smaller upper clamping diameter than the KLX forks, so keep that in mind. I'd imagine by '94 that changed, through '96 (through '97 on the KX500).
I believe the KX125 use a rigid upper triple clamp with integrated bar mounts, and the KX250 and 500 use the vibration isolators similar to the KDX vibration isolator rubbers, although they are a slightly different size and part number versus the KDX version.
I can try and dig this out tomorrow if you haven't found one already, I wouldn't be opposed to selling it. I believe it's actually attached to the 1991 KX lower triple clamp that I had which I had bought because the KX triples using aluminum steering stem and the 1991 fits the KDX / KLX / KX500 frames, 1992+ KX125/250 steering stems are not compatible with the KDX frame due to the inner versus outer bearing diameter not existing that would make this fit.
I would probably need to actually double check and make sure the offset is correct as I never tried to install it as I ended up always being happy with the solid mounted setup on my 220.
KDX250/KLX650 triples (same part number both bikes) maybe the best bet at fitting if they have vibration isolators. Most likely they do I'm guessing from the displacement and piston size lending itself to lots of vibrations. The bonus there is that they have an aluminum steering stem that is the same dimensionally as the KDX steering stem. If it's like a 1991 KX though, it is not hollow, so you can't run your fuel filler cap vent hose into it, and you will need a short stubby hose with a check valve, which is a pretty common setup.
I can check to see if there are any identifying marks on it, there may be the last 4 digits or so of the Kawasaki part # cast into it in typical fashion.
I do know that 1991 KX triples have a smaller upper clamping diameter than the KLX forks, so keep that in mind. I'd imagine by '94 that changed, through '96 (through '97 on the KX500).
I believe the KX125 use a rigid upper triple clamp with integrated bar mounts, and the KX250 and 500 use the vibration isolators similar to the KDX vibration isolator rubbers, although they are a slightly different size and part number versus the KDX version.
I can try and dig this out tomorrow if you haven't found one already, I wouldn't be opposed to selling it. I believe it's actually attached to the 1991 KX lower triple clamp that I had which I had bought because the KX triples using aluminum steering stem and the 1991 fits the KDX / KLX / KX500 frames, 1992+ KX125/250 steering stems are not compatible with the KDX frame due to the inner versus outer bearing diameter not existing that would make this fit.
I would probably need to actually double check and make sure the offset is correct as I never tried to install it as I ended up always being happy with the solid mounted setup on my 220.
KDX250/KLX650 triples (same part number both bikes) maybe the best bet at fitting if they have vibration isolators. Most likely they do I'm guessing from the displacement and piston size lending itself to lots of vibrations. The bonus there is that they have an aluminum steering stem that is the same dimensionally as the KDX steering stem. If it's like a 1991 KX though, it is not hollow, so you can't run your fuel filler cap vent hose into it, and you will need a short stubby hose with a check valve, which is a pretty common setup.
'97 KDX220R - purple/green! - KLX forks, Lectron, Tubliss
'97 KX125/220R hybrid build! - '25 KX450X suspension, titanium hardware, extensive mods purple/green!
'99 KDX220R project - '98/'01 RM125 suspension, Titanium hardware, Lectron Billetron, Tubliss
'77 Suzuki PE250 & '83 PE175 Full Floater - restomod builds
'77 Suzuki GS750-844cc, '77 GS400 & '77 GS550 big bore builds
'62 GMC 1000 Panel Truck
'88 Suzuki Samurai TDI/Toyota swap
'88 Toyota 4x4 pickup
'97 KX125/220R hybrid build! - '25 KX450X suspension, titanium hardware, extensive mods purple/green!
'99 KDX220R project - '98/'01 RM125 suspension, Titanium hardware, Lectron Billetron, Tubliss
'77 Suzuki PE250 & '83 PE175 Full Floater - restomod builds
'77 Suzuki GS750-844cc, '77 GS400 & '77 GS550 big bore builds
'62 GMC 1000 Panel Truck
'88 Suzuki Samurai TDI/Toyota swap
'88 Toyota 4x4 pickup

