KDXRIDER.NET

I got the Pivot Works fork rebuild kit for my 2001 KX500 forks that I'm getting ready to put on my 01 KDX220. The kit comes with a handful of little O-Rings and I saw some little copper washers in there too. What are these various O-Rings and other miscellaneous stuff? I know of the Dust and Oil Seals, as well as the two bushings that are the typical fork replacement items.

Look on the OEM parts diagram at the compression adjuster assembly

I figured that's what that was. Is any of that worth touching? Or does it not really wear down?


Sent from my iPhone using Tapatalk

Well, it is going to be apart, so you might as well.

Yea. I replaced the two outer o-rings on the compression adjuster. And the copper washer. But I didn't wanna mess with the locked in nut and shims and all so I left that alone. Thanks for your help Jason!


Sent from my iPhone using Tapatalk

You are welcome. After you ride it some, if it is too stiff, you may need to do some work on the shims that were on that compression adjuster assembly.

I finished the conversion today. It is absolutely amazing. I've got both the compression and rebound set to 10 clicks out as my starting point. I'm probably 220# when dressed and everything so the stock springs seem to do fine for me off-road. I might need to soften a hair on the compression, but wow it was absolutely awesome. Very solid and stable. I got a few feet of air at one point and it was nice not to plow back into the earth upon landing.

Another question: how high can you comfortably raise the forks in the triples? I've got it 20mm from the top right now. The bottom part of the triple and where the outer fork tube starts to taper back down is my concern. It's kinda twitchy. I might tighten the stem nut down a little more to help but also raise the triple just a hair more.

I've heard, I believe from Tyl3r, one inch, 25mm, above the triple works good?


Sent from my iPhone using Tapatalk

I have a 97' 220 with a KX500 fork swap. The previous owner couldn't remember what year KX500 the forks came from. He told me he just bolted the whole front end on the KDX triple clamps, wheel and all. My KDX also has the 3.6gal Desert fuel tank and at full rotation the fork uppers will hit the tank before reaching the stop tabs. I'm not sure if this is due to the taller fuel tank or if it is a KX500 conversion issue. What can I do to fix it?

rehammer81 My forks also hit my desert tank. If you do a forum search for "Steering stops for klx300 forks?" a member G22inSC who posted a pic in that forum of his solution that I plan on trying. He ground some angle iron and screwed it to the stop on the frame. It looks quick and easy. Have a look.

I am book marking this since I am going to do a KX500 front end swap and also plan on getting a 3.6gal Clarke gas tank.

The stock forks are 43 mm diameter in the "tank hitting area". USD forks are larger OD in that area, so they can hit. Some are 54 or 56 mm for example.

If it just touches the tank I wont worry about it at all. As long as it doesn't want to crack or punch a hole in the tank or something. Checking my stock forks with the stock tank they look to have plenty of room at full lock either side.