Upper Triple Clamp Swap for KDX H series

[96xr250]

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]

CHECK THE OFFSET, but 1991 - 1994 KDX250 may work. Also, 1991 KX250 and 1991 - 1993 KX500.

I can not remember the offsets.

[Chuck78]

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.

[96xr250]

I might just stay with the klx300r triple and buy bar mounts. I was wondering if I could just use the KLX forks in the KDX triple clamps. Are the forks different diameter at the clamping surfaces? If clamping surface is the same, why could not this work? Could not find any answers on this forum. Thanks for any replies.

[Chuck78]

The lower triple clamp tube diameter is all the same across the 43mm forls (EDIT - speaking ONLY of the INVERTED 43mm forks, absolutely not the right side up KDX forks) or so it seems, 1991 - 1995 KX as well as KDX 250 and KLX models through at least 2007 if not 2011. The upper triple clamp diameter for clamping the fork tubes changed slightly as it grew larger around 1993 or 1994 on the KX forks as best as I can determine without having the forks to measure, that's when the forks have larger damping pistons and then upgraded to having a mid valve on the back side of the rebound piston instead of just a check valve. One year of that range got larger damping pistons, the next year got a mid valve as well.
The KLX 43mm inverted KYB forks came out around then also

[JimmyB]

I might just stay with the klx300r triple and buy bar mounts. I was wondering if I could just use the KLX forks in the KDX triple clamps. Are the forks different diameter at the clamping surfaces? If clamping surface is the same, why could not this work? Could not find any answers on this forum. Thanks for any replies.

Unfortunately the forks from the KLX300 do not fit the KDX clamps and vice versa, unless you have the 93-94 e-series or some of the SR models.
The clamp bores are bigger for the USD forks on the KLX300, top clamp is 52.10mm and 56.60mm for the bottom clamp, the KDX is 43mm bore for the top and bottom clamps.

[KDXGarage]

The clamping area is a lot bigger than 43 mm.

I think 1992 - 1995 KX125 / KX250 is a different offset. 1991 - 1993 KX500 is like 1991 KX125 / KX250 / KX500.

[Chuck78]

I might just stay with the klx300r triple and buy bar mounts. I was wondering if I could just use the KLX forks in the KDX triple clamps. Are the forks different diameter at the clamping surfaces? If clamping surface is the same, why could not this work? Could not find any answers on this forum. Thanks for any replies.

Unfortunately the forks from the KLX300 do not fit the KDX clamps and vice versa, unless you have the 93-94 e-series or some of the SR models.
The clamp bores are bigger for the USD forks on the KLX300, top clamp is 52.10mm and 56.60mm for the bottom clamp, the KDX is 43mm bore for the top and bottom clamps.

I edited my reply above to clarify I was definitely NOT speaking of the right side up KDX 43mm triple clamps, they are entirely different than any upside down fork triples, but was speaking only of the '91-'95 KX125/250/500 43mm forks (including 1996 KX500), 91-94 KDX250 blue inverted forks, and KLX 250/300/650 43mm inverted forks. Also, the '93-'94 KDX200E blue inverted KYB forks are 41mm not 43mm, and absolutely do have smaller clamping diameters top and bottom.

[JimmyB]

I might just stay with the klx300r triple and buy bar mounts. I was wondering if I could just use the KLX forks in the KDX triple clamps. Are the forks different diameter at the clamping surfaces? If clamping surface is the same, why could not this work? Could not find any answers on this forum. Thanks for any replies.

Unfortunately the forks from the KLX300 do not fit the KDX clamps and vice versa, unless you have the 93-94 e-series or some of the SR models.
The clamp bores are bigger for the USD forks on the KLX300, top clamp is 52.10mm and 56.60mm for the bottom clamp, the KDX is 43mm bore for the top and bottom clamps.

I edited my reply above to clarify I was definitely NOT speaking of the right side up KDX 43mm triple clamps, they are entirely different than any upside down fork triples, but was speaking only of the '91-'95 KX125/250/500 43mm forks (including 1996 KX500), 91-94 KDX250 blue inverted forks, and KLX 250/300/650 43mm inverted forks. Also, the '93-'94 KDX200E blue inverted KYB forks are 41mm not 43mm, and absolutely do have smaller clamping diameters top and bottom.

Yes, very sorry Chuck, the 93-94 did come with 41mm and the overseas SR 37mm, my mistake, clamps won't fit from these.