'03 KLX300 Forks on an '00KDX200 Install
Posted: 08:33 pm Sep 29 2015
Installed a set of '03 KLX300 forks on my '00 KDX200...
Had the forks rebuilt & re-valved for woods riding at KB5 Suspension in Lebanon, PA.
Had to use Tusk 15mm bar risers because I'm running 1" lowering links in the rear.
Installed new bearings & seals, and drilled & tapped the triple clamp stops for M5 machine screws to extend the stops, the screws required 3 washers on the left side.
Finding a route for the brake line was a challenge - I thought about ordering a stock KLX300 line but the $100+ price tag was a little too stiff
and I didn't trust the used ones on eBay... So, I ended up removing the odometer cable guide from the right fork ( I don't use the odo - I have a Trailtech), trimming about 1/2" off the end of the clamp and using it to pinch a piece of 3/8" hose around the brake line and riveted it to the top of the left guard after notching the top of the guard for the brake line . It seems to work well and everything held together for a 2 hour ride on Sunday. 
I also ordered OEM fork guards from Partzilla for the '03 forks which turned out to be discontinued...
So for anyone who may be considering the same swap with older KLX300 forks, the fork guard numbers (for an '07 KLX300) are as follows:
13070-1264-RZ GUIDE,FORK,RH,WHITE
13070-1263-RZ GUIDE,FORK,LH,WHITE
55020-0196-RZ GUARD,FORK,LH,WHITE
55020-0199-RZ GUARD,FORK,RH,WHITE
92152-0315 COLLAR,8X12.7X4 (5 required)
The forks are a huge improvement over the 15 year old (and most likely not serviced) forks that were on my bike, but I feel like I've lost a bit of turning radius which will take some getting used to...
I'll be pulling the shock off and letting Brad @ KB5 work his magic on that in the next week or so!
Had the forks rebuilt & re-valved for woods riding at KB5 Suspension in Lebanon, PA.
Had to use Tusk 15mm bar risers because I'm running 1" lowering links in the rear.
Installed new bearings & seals, and drilled & tapped the triple clamp stops for M5 machine screws to extend the stops, the screws required 3 washers on the left side.
Finding a route for the brake line was a challenge - I thought about ordering a stock KLX300 line but the $100+ price tag was a little too stiff
and I didn't trust the used ones on eBay... So, I ended up removing the odometer cable guide from the right fork ( I don't use the odo - I have a Trailtech), trimming about 1/2" off the end of the clamp and using it to pinch a piece of 3/8" hose around the brake line and riveted it to the top of the left guard after notching the top of the guard for the brake line . It seems to work well and everything held together for a 2 hour ride on Sunday. I also ordered OEM fork guards from Partzilla for the '03 forks which turned out to be discontinued...
So for anyone who may be considering the same swap with older KLX300 forks, the fork guard numbers (for an '07 KLX300) are as follows:
13070-1264-RZ GUIDE,FORK,RH,WHITE
13070-1263-RZ GUIDE,FORK,LH,WHITE
55020-0196-RZ GUARD,FORK,LH,WHITE
55020-0199-RZ GUARD,FORK,RH,WHITE
92152-0315 COLLAR,8X12.7X4 (5 required)
The forks are a huge improvement over the 15 year old (and most likely not serviced) forks that were on my bike, but I feel like I've lost a bit of turning radius which will take some getting used to...
I'll be pulling the shock off and letting Brad @ KB5 work his magic on that in the next week or so!
