'03 KLX300 Forks on an '00KDX200 Install

Questions and comments about converting to beefier forks..
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K50X200
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'03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

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 :shock: 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. :grin:

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!

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Last edited by K50X200 on 09:55 pm Sep 29 2015, edited 1 time in total.
"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by 6 Riders »

Can you measure the diameter of the fork, where the guides mount?
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

6 Riders wrote:Can you measure the diameter of the fork, where the guides mount?
2 3/8+" (maybe 2 13/32") on the large part - 2 5/16" in the recess
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Or to be more precise... :grin:
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"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by Julien D »

Nice work. Kudos for taking the time to get it done right, and thanks for sharing your info here!
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by 6 Riders »

Sweet! You just found replacement lower guards for USD KDX forks! :supz: :supz: :partyman: :drinkers:
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

Julien D wrote:Nice work. Kudos for taking the time to get it done right, and thanks for sharing your info here!
Thanks Julien - I couldn't have done it with without the the knowledge base available on kdxrider.net! :grin:
"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

6 Riders wrote:Sweet! You just found replacement lower guards for USD KDX forks! :supz: :supz: :partyman: :drinkers:

That's cool! :grin:
They weren't cheap - but after trying unsuccessfully to figure out how to make a $25 set of UFO KX250 guards work with the brake line, they were the best option I could come up with...
"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by Slick_Nick »

I have a spare set of KLX fork guards lying around if anyone wants them. I'll include the guides as well. Ended up using KX guards on my forks as they look and fit much better.
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by 6 Riders »

How much do you want for them?
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

6 Riders wrote:How much do you want for them?
How'd I know that was gonna happen? :lol: :lol:
"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by Slick_Nick »

Haha ****, make me an offer. They're not in the best of shape but otherwise just laying around. Shipping to the good ol US and A should be around $20-$25 I'm guessing... Feel free to PM me.
'00 KDX 220R
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Re: '03 KLX300 Forks on an '00KDX200 Install

Post by ohgood »

congrats, that's a really nice setup. enjoying a gnarley + stock arrestor right now. quiet and torquey, but those forks must be sweeet
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'03 KLX300 Forks on an '00KDX200 Install

Post by thirdgenlxi »

Very nice! So were any modifications needed for the triple tree or bearings to work on the KDX? Or did everything just bolt right on? Same axle and everything too? I'm seriously thinking of doing this swap here before too long
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'03 KLX300 Forks on an '00KDX200 Install

Post by K50X200 »

thirdgenlxi wrote:Very nice! So were any modifications needed for the triple tree or bearings to work on the KDX? Or did everything just bolt right on? Same axle and everything too? I'm seriously thinking of doing this swap here before too long
Nope no mods needed for the basic fitting of the triples... but you will need to adjust the stops (unless you don't mind the forks hitting the tank!) and you'll need to work out a route for the brake line.
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'03 KLX300 Forks on an '00KDX200 Install

Post by thirdgenlxi »

Awesome.... Thanks! I think I'm definitely gonna do it, and probably take them into Ohlins here locally and have him work some magic. All that after supermoto wheels though.... Thata my first project, haha
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