'90 KDX200 to '92 KDX250 forks

Questions and comments about converting to beefier forks..

'90 KDX200 to '92 KDX250 forks

Postby criggs9901 » 04:20 pm Aug 09 2018

Recently came up on a set of forks from a '92 KDX250 for super cheap, figured I'd get them and throw em on the 200. I know they aren't as much of an upgrade as the KX forks, but the person riding this bike really doesn't need the KX stiffness, plus the deal was too good to pass up. The only problem is that I can't find much info on this particular swap. Spent a few hours scouring this site, so I hope I don't ask any repeat questions here. Does anyone know for sure if the stem needs to be swapped, or will the one from the 250 work? Also does anyone know for sure if the caliper positioning is the same? I did swap the wheel over and confirmed it does fit nice and centered, and the 200 and 250 share part numbers for the brake caliper, but I couldn't tell if the disc lines up properly yet. Also, last thing, is there a particular guide I should look up to rebuild these forks? Never done them before, and I'd rather not buy a service manual for the 250 just for the fork service.

I'll be swapping and mounting everything this weekend to see what happens, just hoping to have as much info as possible when I start tearing into it. Thanks so much, guys.

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Re: '90 KDX200 to '92 KDX250 forks

Postby Jason » 06:16 pm Aug 09 2018

The clamps will swap right over.

Do you not have any fork guards?

I am not sure on disc compatability. I know you can't use a 1989 - 1992 KDX200 caliper, as it won't lt up to the hanger (caliper bracket).

There is a KYB fork service article in the sticky threads in this subforum.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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'90 KDX200 to '92 KDX250 forks

Postby criggs9901 » 07:14 pm Aug 09 2018

Awesome, thanks so much for the info. It didn't come with guards, but I have a set on the way. The brake situation definitely has me confused, because the part number I looked up showed the same for both bikes, but everyone says they don't match. Guess I'll find out this weekend =P.
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'90 KDX200 to '92 KDX250 forks

Postby david » 07:35 pm Aug 09 2018

criggs9901 wrote: The brake situation definitely has me confused, because the part number I looked up showed the same for both bikes...


You didn't look up the complete part number
'90 200 43041-1312
'92 250 43041-1427
'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
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Re: '90 KDX200 to '92 KDX250 forks

Postby Jason » 05:39 am Aug 10 2018

The number on the diagram is the reference number, not the part number. A part number is 12345-6789, not 12345.

Stock brake hose routing on the KDX250 is a lot different than the current setup you have. Look at the online diagrams and some various KDX250 pics online. A line runs up under the fork to a hose.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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'90 KDX200 to '92 KDX250 forks

Postby criggs9901 » 09:57 am Aug 10 2018

Yup, you're right, I did some more checking last night and I think I just got some numbers confused. Looks like I will have to at least get a caliper, and probably a brake line too.
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'90 KDX200 to '92 KDX250 forks

Postby criggs9901 » 11:49 pm Aug 18 2018

So here's what I've discovered about this swap so far. The E caliper will mount on the 250 forks, but the piston sits further forward than needed and won't allow the wheel to slide all the way in.
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I end´╗┐ed up finding a used KDX250 caliper on eBay, got it in yesterday and mounted it up to see how the wheel looked. Everything bolted in fine, the caliper now lined up with the wheel, but it sits slightly too far inward for the original E wheel, causing the brake rotor bolts to just barely rub on the inside of the caliper bracket (different offset on the rotor? Different wheel spacers? Hard to tell, the wheel seems to be perfectly centered).
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During some research, I came across a thread on this site of someone who swapped KLX forks to his E series and was able to use the original front wheel with some caliper bracket modifications. So I took the bracket to work this morning and performed the necessary mods. Didn't get a chance to mount it up yet, but will be doing that tomorrow, so I'll let ya know how it goes. As always thanks so much for the info.
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Re: '90 KDX200 to '92 KDX250 forks

Postby Jason » 07:36 am Aug 19 2018

Good luck on it! Thanks for the "try it and see" info! :bravo:
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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