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It turns out that the 95 KX lower tree is a .20 larger hole than the 95 KDX stem. Had to be knurled, filed and knurled again to get a good tight fit.

So, expect some extra cost when you have this done. It cost me $55 to have them swapped out. I was not expecting that and they didn't take plastic.

They could tell I was pissed at the extra cost, so while I was driving around looking for a ATM, they called the guy that did it to get and explaination. He said the KX was extremely hard to get out and took a lot ef extra time going through heating and cooling cycles trying to get it to press out. Then the tolerance issues with the KDX stem to KX lowers.


It's done, and overall I'm happy..... OVERALL.

Wow, at least he could draw .2" out!!

Upon closer inspection....

The machinist was a dumbass.

He pushed the stem through the wrong way. This is why it was so difficult. I checked the lowers and can't find any stress fractures but I paid for his ignorance.

On the other hand... the KDX one he did correctly.

I can tell he pushed it through the wrong way by the missing aluminum lip on the KX stem. It's not there and sheared off.

I really need to start doing this **** myself.

Well... got them on and soft fitted.

They fit better than the 03's on my bike. Very balanced after using Phil's fabricated spacer (Thanks Phil!)

This conversion is going buttery smooth.....

Where is Phil. Anyone heard from him????

He wrote me and said he moved and was working alot of overtime along with riding. He said when things slow down he will stop in.....

Vince-When he writes, let him know to drop me a line when he gets a chance. Thanks

Vince, I must have missed something. You're doing another bike? Where'd that one come from?

Anyway, I took my lowers to the dealer and they swapped the stems for $22.50 I thought that was a decent deal for a bike shop. The dude that did it has done it before and knew what he was doing.

Well... here in the midwest... folks smoke alot of dope. And even though he did it last year for me after I gave him specific instructions... he funked it up. Turned out OK though.... just cost over twice the price. Last time he charged me $25. Guess he's getting low on weed.

Yeah... I bought a $500 95 KDX project and my brother traded me for my old 77 Triumph Bonneville back as long as I got the bike up to snuff.

So, I am doing everything I can to make it a very trail worthy bike since the Triumph is worth many times of what a KDX is.

Gotta love brothers!

I hear you. Mine gave me an autographed Steve Largent Jersey for Christmas last year! (I used to live near Seattle)

If that guy shoved the KX stem through that lower KX clamp wrong, then I would not use it. That thing was way too stressed, even if there is nothing obvious. The heat/cool cycle you mentioned could have crystalized the aluminum and make it very brittle. If it were me, I'd go back, point out his error, ask for a refund and cost of the clamp, then buy a new clamp and start all over. At the very least, a refund on the charge due.

I would not ride that bike with that clamp knowing that the stem was shoved out of it the wrong way. It's incredible that it didn't break.

skipro3 wrote:If that guy shoved the KX stem through that lower KX clamp wrong, then I would not use it. That thing was way too stressed, even if there is nothing obvious. The heat/cool cycle you mentioned could have crystalized the aluminum and make it very brittle. If it were me, I'd go back, point out his error, ask for a refund and cost of the clamp, then buy a new clamp and start all over. At the very least, a refund on the charge due.

I would not ride that bike with that clamp knowing that the stem was shoved out of it the wrong way. It's incredible that it didn't break.

Vince-Don't let your brother read this thread

Perhaps Vince doesn't think too highly of his bro and that's why he's not too concerned about the lower clamp.

Perhaps I took it to Caterpillar and had them run a stress test on it in the Met Lab and it checked out fine?

Whew!!

Next time take a doob to the shop