'03 KLX300 Forks on an '00KDX200 Install
- K50X200
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'03 KLX300 Forks on an '00KDX200 Install
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 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.
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!
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 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.
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!
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
Can you measure the diameter of the fork, where the guides mount?
newbbewb wrote:^what he said.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually typemasterblaster wrote:Man 6 riders you rock.
- K50X200
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Re: '03 KLX300 Forks on an '00KDX200 Install
2 3/8+" (maybe 2 13/32") on the large part - 2 5/16" in the recess6 Riders wrote:Can you measure the diameter of the fork, where the guides mount?
Or to be more precise...
"00 KDX200 - Baja Designs D/S Kit, '03 KLX300 Forks, KB5 Suspension Mods, Keihn 35 ASQV, Boyesen Rad Valve, Gnarly Woods Pipe
- Julien D
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Re: '03 KLX300 Forks on an '00KDX200 Install
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
Sweet! You just found replacement lower guards for USD KDX forks!
newbbewb wrote:^what he said.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually typemasterblaster wrote:Man 6 riders you rock.
- K50X200
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Re: '03 KLX300 Forks on an '00KDX200 Install
Thanks Julien - I couldn't have done it with without the the knowledge base available on kdxrider.net!Julien D wrote:Nice work. Kudos for taking the time to get it done right, and thanks for sharing your info here!
"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
6 Riders wrote:Sweet! You just found replacement lower guards for USD KDX forks!
That's cool!
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
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
How much do you want for them?
newbbewb wrote:^what he said.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually typemasterblaster wrote:Man 6 riders you rock.
- K50X200
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Re: '03 KLX300 Forks on an '00KDX200 Install
How'd I know that was gonna happen?6 Riders wrote:How much do you want for them?
"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
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
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
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
- K50X200
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'03 KLX300 Forks on an '00KDX200 Install
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.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
"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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'03 KLX300 Forks on an '00KDX200 Install
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