KDXRIDER.NET

i keep seeing it mentioned in here about removing parts of a shim stack in the forks, i have an 01 kdx200 with 01 kx250 forks, and the thing rides like a truck! i am getting ready to change the fork oil to amsoil lite5, and was wondering how involved it was to alter the shim stack and what exactly do i need to do? or should i just change the fork oil and hope for the best? i am 170 lbs, amateur rider. thanks!

Aside from changing the oil, you should check the springs to make sure they are correct for your weight.

The mechanics of a revalve aren't difficult, knowing what to change is the hard part. Fortunately those forks are common and if you can't find shim stacks for woods riding here, you should be able to find something in the suspension forum on thumpertalk. That will at least get you closer than what you have now.

If you are going to go through with doing a revalve yourself, make sure you change the bushings (unless you know they have been replaced recently).

I have a page on my site that shows the "tools" I made to work on my OC forks.

I just removed 3 shims and oil quantity on my 2001 220 and am happy. Places that I would have had problems are not as scary any more. I weigh 135 so the springs are good fore me, also changed the rear spring to a 4.6.

01's are bladder forks. Bladders make compression really stiff and not good on the trail. You probably need to remove them. I did a complete write up in 07 on the 01's and the bladder removal and shim stacks.

I have read it, it feels great.

Hi, so I'm struggling to track down the correct combination info on the forum for adjusting 2002 KX 250 fork for woods riding. I'm after correct info on:

- shortening (how much, and how, not just sliding the forks up),
- re-valving (I'm 220lbs with gear),
- oil wight (5?)
- suggested spring rates (if they differ from say RaceTech recommended).

Any pointers appreciated. Chris.

2002 KX 250 FORK ON A 2002 KDX 220

- shortening (how much, and how, not just sliding the forks up),
You don't shorten them, you do slide them up about 1" above the triple clamp. The rear shocks are shortened 1" if you use a RM shock.

- re-valving (I'm 220lbs with gear)
remove all but 4 (usually about 5-7) of the 25mm shims in the base valve. Heavy riders may use 3.
Remove the bladder and the bladder's hardware.

- oil wight (5?)
yes

- suggested spring rates (if they differ from say RaceTech recommended).
go with whatever race tech suggests.

Cut groves in the restrictive barrier.

Great, thanks for the info.

So there's no chance of the tire hitting the fender with the forks moved up an inch in the triple clamps?

Just been checking out the 2002 fork assembly diagram to understand the bladder situation before I get at it. Might be blind, but I can't make out a bladder in any year that I've checked from 2005 to 1997. Which part # is it?

2005 KX250-N2
http://www.partzilla.com/parts/search/K ... parts.html

2004 KX250-M2
http://www.partzilla.com/parts/search/K ... parts.html

2003 KX250-M1
http://www.partzilla.com/parts/search/K ... parts.html

2002 KX250-L4
http://www.partzilla.com/parts/search/K ... parts.html

2001 KX250-L3
http://www.partzilla.com/parts/search/K ... parts.html

2000 KX250-L2
http://www.partzilla.com/parts/search/K ... parts.html

1999 KX250-L1
http://www.partzilla.com/parts/search/K ... parts.html

1998 KX250-K4
http://www.partzilla.com/parts/search/K ... parts.html

1997 KX250-K4
http://www.partzilla.com/parts/search/K ... parts.html

The bladder didn't show up in any drawings I have ever seen. I have pics. Send me your email and I'll send you the complete rebuild doc with pics. Also shows the restrictive barrier modified. It is simply a large flat washer the spring sits on with grooves cut into it.

Will do, I'm not authorized to send or read PMs on here for some reason, I'll shoot an email to the address on your profile.

Would you be willing to shoot me a copy too? Thanks!

Here's a link to what I wound up doing, was relatively cheap and now the bike rides great for trail riding and is totally balanced. My friend who is a b rider rode it before the mods, and returned the bike promptly. After the mods he took it and disappeared for a while and came back with a smile on his face! We all weigh aprox 170 lbs.