2004 KX500 fork on a 2000 KDX 200

Questions and comments about converting to beefier forks..
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Jupiter2
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2004 KX500 fork on a 2000 KDX 200

Post by Jupiter2 »

I got the itch to do the kxkdx fork swap. Being a somewhat un-mechanical type I decided to go the kx500 route. Several posts on this site suggest is a straight bolt on and I wouldn’t have to deal with machining parts. Less for me to deal with for my first mod...

At this point I have a 2004 KX500 forks/triple tree, wheel hub, axle and spacers being shipped. I also have a full wheel off a 98 KX500. I was planning on putting the forks on a 2000 KDX 200.

I was planning on using the brakes (caliper, cable and master) off of the KDX thinking they were interchangeable. Unfortunately I did not do all my homework ahead of time because it appears the calipers from 2000 KDX will not work on a 2004 KX fork. After looking up part numbers on front calipers, as far as I can tell, the 04 KX500 caliper is only interchangeable with 04 - 06 KDX’s. The 2000 KDX caliper is only cross referenced up to the 03 KX500.

Never having done this before I was hoping those in the know could confirm or deny this for me and possibly guide me in the direction I should take.
gregf@aimcom.com

2000 KDX 200
2002 XR200
Kazuma 90cc quad
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Indawoods
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Post by Indawoods »

They are exactly the same....
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Julien D
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Post by Julien D »

Should be fine, yep.
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Jupiter2
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Post by Jupiter2 »

Very cool thank you. That makes me feel much better.
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2002 XR200
Kazuma 90cc quad
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Post by jbowens2401 »

I have a 2005 kdx 220 and I would like to do a kx 500 fork swap. Are these all of the parts I need:

forks
triple tree
full wheel
axel and spacers

What year kx forks are a direct bolt on? Are there any particular years I should stay away from? I know the newer forks will have better technology...how far back should I go in year model...nothing older than 2000 maybe?

Thanks,

John
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Indawoods
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Post by Indawoods »

Nothing older than 96
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****'95 KDX 200/****

"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
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Post by jbowens2401 »

thanks inda,

is my list of needed parts correct? if so, i will start shopping ebay if i don't hear back from the guy in the for sale section with the 2000 model forks and triple.

thanks,

john
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Post by Indawoods »

Yep... looks good. You should be able to reuse the KDX caliper.....
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Post by jbowens2401 »

Thanks for the help.
Jupiter2
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Post by Jupiter2 »

Believe it or not I actually managed to do the fork swap last weekend! Not to complicated even for me... Slow and steady. Also had to build a new wheel as well. I actually found building the wheel pretty fun.

Ok, even though i got everything together and it all seems to be ok I did not put a "final" tightening on everything because I can't find the torque settings.
Is it ok to just snug everything down by "feel"?
Does anyone know where i can find the torque settings for all the bolts on a 04 KX 500 front fork? Tripple clamps, handel bars and wheel holders?
gregf@aimcom.com

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2002 XR200
Kazuma 90cc quad
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Indawoods
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Post by Indawoods »

10-12ft lbs on the clamps.
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Post by Jupiter2 »

Cool. Thanks Inda. Just in time for a ride tomorrow. :grin:
gregf@aimcom.com

2000 KDX 200
2002 XR200
Kazuma 90cc quad
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Post by mercenary223 »

How are the 500 forks working out for you and how much do you weigh. I am either going to get my stockers rebuilt or swap deppends on price difference but from hearing everyone the swap seems straight forward. I have a 1991 but I think the swap would be about the same. Thanks for your time.
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Post by Jupiter2 »

New forks work great. I putz around at my buddies track a lot and they've made a big difference there. They are a whole different feel on the trail too. Took me a couple rides to get used to but I love'em. One of the seals is starting to seep a bit so I'm planning on taking them in to have the seals replaced and see if the guys at the shop can tell me what springs are in it. I just threw these things on and have no clue what weight rider they were setup for. I weight in at 175lbs. At this point its all about money...cause i don't have any... lol
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Post by bmiller »

can you post pictures? I'm gathering the wits to do this on my 2000 KDX 200 with 2001 KX500 forks.
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Post by fuzzy »

At this point its all about money...cause i don't have any
Then change the seals yourself. The springs might actually have a stamp on them. Did they feel too stiff or too soft? At 175 you may be OK, but I'm not sure about these forks. More often than not the spring will be correct, but harshness is all in the valving.
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Post by Byte »

.....are there any changes between 2001 kx500 forks to 2004/5 kx500 forks?

(better technology, etc)?


Byte
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