Knurled Stem

Green Hornet · Post by **Green Hornet** » 02:43 pm Nov 08 2005

Why does the stem have to be Knurled??

Post by **KDXGarage** » 02:55 pm Nov 08 2005

Some have mentioned that in order to maintain the proper fit, machine work is necessary to use the KDX stem in the KX lower clamp. Some have had the KDX stem knurled. Some have had the stem hole knurled.

If there was no machine shop work involved, KX front ends would be $1,000 each and KDX front ends would be $100 each. SHIPPED!!

Green Hornet · Post by **Green Hornet** » 03:03 pm Nov 08 2005

Now, what dimensions do I need it Knurled too? What info do I need to give a Machine Shop??

Post by **KDXGarage** » 03:10 pm Nov 08 2005

Make it fit?
Make it work?
Here ya go?

Sounds like I don't know.

Maybe some of the otehr guys will chime in, but I think it may be best handled by the machine shop, as that's what they do. Different years of KDX or KX may be quite different as far as an exact measurement, also. What may have worked for someone else may not work for you.

skipro3 · Post by **skipro3** » 04:13 pm Nov 08 2005

Not all stems and clamps need knurling. It seems only certain years do. For example: My 1999 KDX stem and 1996 KX clamp needed to be knurled. The machine shop charged me $15. When you take the parts in to be pressed apart and back together, you will know.

Green Hornet · Post by **Green Hornet** » 05:07 pm Nov 08 2005

So if the stem does not fit correctly into the lower TT then it needs to be Knurled & then the Machinist will have to make the adjustment. Correct.

skipro3 · Post by **skipro3** » 05:26 pm Nov 08 2005

Yes. The knurling reshapes the metal on the stem or clamp but does not remove metal. Inda has a nice drawing on here somewhere what that would look like and you could use to show your machinist. On a pair that needs the knurling, the stem will fit the clamp, just not snug. Remember to press the stem off, DOWN not UP!!! Be sure your machinist understands or it will damage the lower clamp. There is a groove and ring on the stem so it can't push any further in than required. Look at it. It's got a taper. I don't know how someone could possibly mistake and press the wrong way, but EVERY machinist I've shown this to has attempted it that way. I insist on being present.

Post by **Indawoods** » 11:31 pm Nov 08 2005

Green Hornet · Post by **Green Hornet** » 11:18 am Nov 10 2005

Ok now. I got the TT yesterday. They are for the 48mm forks. Now the solution. I will use a shim, but have it flared at the top and bottom, so when it is tightened it will act like one piece. Just like those inserts that go into the after market TT. The inserts allow you to change fork sizes, by shanging out the inserts. Does anyone know where I can get those inserts? Any other ideas???
PS. The 03 KX brakes bolt right up to the 01 forks

Post by **KDXGarage** » 11:26 am Nov 10 2005

If you find these shims, please let me know. I am curious to see them.

KDXer · Post by **KDXer** » 11:31 am Nov 10 2005

Sorry, couldn't resist.

Green Hornet · Post by **Green Hornet** » 11:44 am Nov 10 2005

Jason wrote:If you find these shims, please let me know. I am curious to see them.

http://www.dirttricks.com/offset_triple_clamps.htm

Post by **KDXGarage** » 11:54 am Nov 10 2005

Thanks for the links. Actually, those are to change offset, and they just fit those clamps. Even if you could buy just the bushings, it would probably still be cheaper to just buy some proper year model KX clamps.

EDIT!! I would like to sincerely apologize to ALL

group members for not taking the opportunity to crack on a KTM. I am truly sorry to have missed this when I first posted. Please forgive me.

If KTM's are so gosh darn well engineered, why are they the first make pictured in the offset changing clamp photo? We gonna sell a million of these here offset triple clamps, I tell ya!!

KDXer · Post by **KDXer** » 11:56 am Nov 10 2005

Or the good stuff !!!

Green Hornet · Post by **Green Hornet** » 12:04 pm Nov 10 2005

I know there for offset, but the same principle and easy to make.

KDXer · Post by **KDXer** » 12:10 pm Nov 10 2005

Maybe with some measurements and some liquid persuasion dlnoss could punch them out if you have too much trouble sourcing some good sleeves.

Green Hornet · Post by **Green Hornet** » 12:18 pm Nov 10 2005

I'll get a thin Brass, Etc., Flange the ends & round using the forks, then fit into the TT holes and see how it comes out

KDXer · Post by **KDXer** » 12:34 pm Nov 10 2005

Sweet... Good luck with it. Some possible options. Jason should be able to verify fitment.

http://cgi.ebay.com/ebaymotors/RG3-Trip ... dZViewItem

http://cgi.ebay.com/ebaymotors/KAWASAKI ... dZViewItem

Post by **KDXGarage** » 12:51 pm Nov 10 2005

1. I'd check RG3's site for info on these magic Suzuki/Kawasaki combo clamps.

2. FLAT OUT NO, IT WON'T WORK

The proper set of clamps would be '99 - '01.

Green Hornet · Post by **Green Hornet** » 02:50 pm Nov 10 2005

After placing two (2) Unsucessful orders w/BikeBandit, I received notification that my Spacers & Caps for the KX Wheel have been shipped.
Three times is a charm

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Knurled Stem

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Knurling

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