92 KDX KLX 300 Forks Swap

Questions and comments about converting to beefier forks..
KDW
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Re: 92 KDX KLX 300 Forks Swap

Post by KDW »

LINK TO SHARED ALBUM

https://goo.gl/photos/3NeP3VhM4Vz85iN79

So you can browse the pictures a little easier.
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Re: 92 KDX KLX 300 Forks Swap

Post by KDXGarage »

So, an E brake system with the KLX300 forks?

Good job!
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Re: 92 KDX KLX 300 Forks Swap

Post by KDW »

The calliper is from a KLX300. The E brake line and MC should work. Will update.
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Re: 92 KDX KLX 300 Forks Swap

Post by KDXGarage »

So, an early E wheel?
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92 KDX KLX 300 Forks Swap

Post by KDW »

Yep

all that is needed for the swap is

Forks
Calliper
Axle (e spacer is even the same)
Fork Guards

As I said I am yet to bolt up the brake line but it looks like it will work just fine.
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Re: 92 KDX KLX 300 Forks Swap

Post by KDW »

I will know when the guards get here but I might have to hack a chunk out for the brake disk. It is a good 3/16-1/4" closer to the fork leg than the stock 300 set up.
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92 KDX KLX 300 Forks Swap

Post by KDW »

OK... results!

Imageimage by Kristoffer Welch, on Flickr

Imageimage by Kristoffer Welch, on Flickr

Imageimage by Kristoffer Welch, on Flickr

The brake hose routing works but you have to stick it out the side like the picture because of the stock hose fitting. Still better than the KLX300 routing IMO.

Imageimage by Kristoffer Welch, on Flickr

Just got it all done, I will post a summery of the process this weekend if I can find the time however I might be riding!
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Re: 92 KDX KLX 300 Forks Swap

Post by KDXGarage »

Looking good!

Santa Cruz hand! :partyman:

The forks do make the front end look a lot better.

Look on some 1987 - 1989 KX parts diagrams for better upper brake hose routing.

You might also read up a couple of guys here have a brake hose clamp mounting plate on their guards. It seems to work well for them.
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92 KDX KLX 300 Forks Swap

Post by KDW »

Yeah I just had the brake line tucked in there to keep it out of my way while I figured things out. I need to get another guide for the top. It does look allot better. Didn't get a chance to ride (well I did do some street riding) this weekend to test it. I will post once I get a chance to ride it. I live in the City so it's a bit of work just to get it out where I can ride it.
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