1990 KDX200 fork upgrade

Questions and comments about converting to beefier forks..
kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

Hi, this is my first post. My wife has a 1990 KDX200 which she's had for about ten years. We'd like to upgrade the suspension for her, not necessarily to upside down forks, but to forks from a later model with better damping and valving. I was looking at the parts fiche for suspension components and it seems that from 90-92 the suspension is like hers, 93-94 is improved, but starting in 1995 it looks like they got cartridge forks. I am looking to find a fork type which I can send to my suspension guy and have it sprung for her weight and riding ability, something that can't really be done on her present forks. She not a fast rider, but she feels that the forks are holding her back at higher speeds compared to when she rides my modern KTM. We ride the California desert and mountains.
I don't know if upgrading to 1995 or better is a good plan or not. I would like to have a bolt-on conversion. Can you-all tell me whether I would need to buy brake caliper and front wheel/axle to go along with such an upgrade? It looks like the triple clamps are the same from 1990 to 2000. Please give me your recommendations.
Thanks in advance.
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diymirage
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Re: 1990 KDX200 fork upgrade

Post by diymirage »

if it turns out 96 forks are an option for you let me know, i have a set of those i just pulled of off my KDX
id love to part with those for a small fee ;)
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

Mirage, If it turns out that '96 forks are what I want I'll contact you. Meanwhile, I haven't gotten any advice from anyone. I'm going to continue searching this forum for information.
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diymirage
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Re: 1990 KDX200 fork upgrade

Post by diymirage »

no prolbem

there are a few different upgrades i know about but to be honoust i dont know if there is a difference between the 1990 and the 1996
the most popular upgrades are the upside down forks, KX KLX that type of thing
most of those use the upper and lower tripple clamps from the donor bike and the steering stem from you KDX
depending on the bike you get the forks from you need the front wheel and axle aswell

but i would imagine swapping between a 90 and a 96 KDX might not need all that
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

Mirage,
Maybe someone will chime in and tell me what-all is required to go from 90 to 96 forks and whether it's a significant improvement. I'm looking for something bolt-on. My wife doesn't ride that fast. The suspension is great in the mountains, but in the desert it could use better damping. Do you have the rest of the front end for sale as well? In searching this forum I noticed that you put on KX 125 forks on your bike. I probably don't want to undertake something like that.
Thanks.
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Julien D
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Re: 1990 KDX200 fork upgrade

Post by Julien D »

If you would post up with your wifes riding weight and ability along with a description of your normal terrain that would help us give advice. MX fork swaps are pretty common, at varying levels of difficulty depending on what you want or need. H series forks would be an improvement over what you have now for most situations, along with being very easy to install. For more aggressive riding, there are better options. An MX swap like kx forks is not very difficult.
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kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

Julien,
My wife weighs about 130, is 5'5" and is an intermediate rider, but not a fast rider. She has really good technical ability and can handle moderate to difficult terrain pretty well. She loves her KDX, but believes that the suspension is holding her back in the desert at slightly higher speeds over unfamiliar terrain. She has to be careful at what speed she hits obstacles. When she rides my KTM 250 2-stroke she loves the suspension but not the height. She would never ride it in the mountains, however, because she can't touch the ground easily and is scared of riding off the trail down an embankment. The seat height on her KDX suits her very well and she feels very secure on it. So I've heard that you can work with the later model KDX forks to make them perform much better than the 1990's. The bike's ride is so plush right now that I'm not sure I want to harshen up the ride with USD forks. She'll be 50 years old in 6 months. She raced desert for 5 or 6 years but has been riding less lately. She was third in her class a couple of years ago.
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diymirage
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1990 KDX200 fork upgrade

Post by diymirage »

kdxlnt wrote:Mirage,
Maybe someone will chime in and tell me what-all is required to go from 90 to 96 forks and whether it's a significant improvement. I'm looking for something bolt-on. My wife doesn't ride that fast. The suspension is great in the mountains, but in the desert it could use better damping. Do you have the rest of the front end for sale as well? In searching this forum I noticed that you put on KX 125 forks on your bike. I probably don't want to undertake something like that.
Thanks.

i used the KDX tripples and brake set up along with the KX forks , stem and wheel

so i have for sale the KDX forks, the wheel (speedo doesnt work but i dont know if it is in the drive, the cable or the meter itself) and a fender
let me know if you want a shipping qoute and ill see how much it would be

congrats on the wife by the way, its tough finding one who apreciates our hobby, let alone indulge in it aswell
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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KDXGarage
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1990 KDX200 fork upgrade

Post by KDXGarage »

Hi. The 1995+ conventional fork tubes would fit in the 1990 clamps. I am not sure about using the same wheel or not. The caliper does not mount the same.

It sounds like she is the one person on earth that the stock fork springs are the correct weight for. (they are soft!!)
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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Julien D
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Re: 1990 KDX200 fork upgrade

Post by Julien D »

Yup, might not be a bad option and you should be able to get a set cheap.
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diymirage
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1990 KDX200 fork upgrade

Post by diymirage »

Jason wrote:Hi. The 1995+ conventional fork tubes would fit in the 1990 clamps. I am not sure about using the same wheel or not. The caliper does not mount the same.

It sounds like she is the one person on earth that the stock fork springs are the correct weight for. (they are soft!!)
seems to me we need to find out if the axle is the same between the years, if that is the case it sounds like you could use my forks with your tripples and wheel/brake set up
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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KDXGarage
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1990 KDX200 fork upgrade

Post by KDXGarage »

The 1989 - 1992 caliper mounts differently than the 1995+ caliper, doesn't it??
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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diymirage
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1990 KDX200 fork upgrade

Post by diymirage »

Jason wrote:The 1989 - 1992 caliper mounts differently than the 1995+ caliper, doesn't it??

if that is the case i do have a 99 KX front caliper i can ad in with the 96 KDX forks
the mounting is the exact same as my 96 KDX but the unit itself is slightly smaller (which with your wifey on it shouldnt make a difference)

did i mention i also have the 96 KDX front wheel and rotor for sale ?
:whistle:
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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SS109
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1990 KDX200 fork upgrade

Post by SS109 »

Jason wrote:The 1989 - 1992 caliper mounts differently than the 1995+ caliper, doesn't it??
Yep. I ran into that problem when I switched to KX forks. I had to change my '90 caliper out for a '95+ one.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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diymirage
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Re: 1990 KDX200 fork upgrade

Post by diymirage »

so how does the 90KDX caliper compare to the 99KX caliper?
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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Re: 1990 KDX200 fork upgrade

Post by SS109 »

diymirage wrote:so how does the 90KDX caliper compare to the 99KX caliper?
Well, the '90 is a single piston type whereas the '95+ calipers are dual piston. Plus, the caliper bracket and caliper both are different in their mounting from the '89-'92 brakes. Performance wise, it is definitely a step up in stopping power.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

The axles aren't the same, but the 96 is available on ebay. The front calipers are different, but also available. I wonder if I would need a new brake line also?
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1990 KDX200 fork upgrade

Post by SS109 »

I used my stock brake hose and routed it outside the fork when I first did the conversion. To route inside the fork you either need the newer style hose or do some creative bending of the stock banjo fitting. I went for the latter on my current build.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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diymirage
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1990 KDX200 fork upgrade

Post by diymirage »

kdxlnt wrote:The axles aren't the same, but the 96 is available on ebay. The front calipers are different, but also available. I wonder if I would need a new brake line also?

if your interested in the set up i have it includes both forks, a 99 KX caliper (not as good as the KDX version but still better then the one you have now) and if you need it, the wheel, axle and even the front fender

call within the next 5 minutes and ill toss in the 99 KX brake line FOR FREEEEEEEEEEEEEE :bravo:
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
kdxlnt
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1990 KDX200 fork upgrade

Post by kdxlnt »

Mirage,
I'm going to check with a local suspension tuner who used to be a Team Green mechanic and ask him what he suggests for the KDX. He's on vacation right now, but I'll get back to you after I talk to him. If your stuff is sold by then I'll understand. Thanks.
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