My $150 1993 KDX 250 rebuild

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My $150 1993 KDX 250 rebuild

Post by KDXGarage »

snopro753 wrote:I'm going to sell this bike and parts as a project bike. Anyone interested? Clean Iowa title. I bought a KTM and spend all my free time racing Hare Scrambles and Enduros.
Well, sorry that you were not able to complete it. I am going to lock this thread and let you start a new FS thread in the Foe Sale section. Be sure to put prices on the items, with location.

Thanks.
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Re: Kdx250 fork swap

Post by snopro753 »

(Moved from a different thread)

Jason, sorry for bumping an old thread. I have a KDX250 that I had planned to swap over to 1998 KX250 forks and 1999 KX125 triple clamps.

I am recall an old thread I can't find it, where someone used a newer KX125 clamp with a top bearing that fit the KX125 stem but the KDX250 original race. A conversion bearing. Do you ever recall this?

If not, do you recall if a KDX250 stem can be pressed into the 1999 KX125 triple clamps and complete the conversion that way?
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Re: Kdx250 fork swap

Post by KDXGarage »

(Moved from a different thread)

No problem, especially with such a cool avatar. :cool:

I think there is no magical bearing, as no one would be swapping stems otherwise.

Though the 1998 KX250 lower clamp is the same as the 1999 KX125 lower clamp, the 96-98 upper has different tube hole sizes than 99-01.

If I remember correctly, a KDX250 stem is about 7 thousandths smaller OD than the later KX stems. 1996 KX125 / KX250 is even bigger!

If you want 1998 KX250 forks, get 1998 clamps or go buy a 96-98 upper to go with the 98-01 lower.
snopro753 wrote: 09:22 pm Jan 12 2020 Jason, sorry for bumping an old thread. I have a KDX250 that I had planned to swap over to 1998 KX250 forks and 1999 KX125 triple clamps.

I am recall an old thread I can't find it, where someone used a newer KX125 clamp with a top bearing that fit the KX125 stem but the KDX250 original race. A conversion bearing. Do you ever recall this?

If not, do you recall if a KDX250 stem can be pressed into the 1999 KX125 triple clamps and complete the conversion that way?
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Re: Kdx250 fork swap

Post by snopro753 »

(Moved from a different thread)
KDXGarage wrote: 01:51 am Jan 13 2020 No problem, especially with such a cool avatar. :cool:

I think there is no magical bearing, as no one would be swapping stems otherwise.

Though the 1998 KX250 lower clamp is the same as the 1999 KX125 lower clamp, the 96-98 upper has different tube hole sizes than 99-01.

If I remember correctly, a KDX250 stem is about 7 thousandths smaller OD than the later KX stems. 1996 KX125 / KX250 is even bigger!

If you want 1998 KX250 forks, get 1998 clamps or go buy a 96-98 upper to go with the 98-01 lower.
Thanks for the fast reply. My memory is fuzzy because it's been 5 years since I researched this topic. I looked back through my original build thread and found out my forks are 1997 KX125. Would you be willing to unlock my thread again? I started building this bike again after a long hiatus.

viewtopic.php?f=77&t=17644

So with my 1997 KX125 forks I can use 1996-1998 125/250 top clamps correct?
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

I have unlocked this thread as requested by snopro753.
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

Yes, 1997 KX125 forks are 1996 - 1998 KX125 upper clamp (or KX250 for rubber mounted handlebar clamps)
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Re: My $150 1993 KDX 250 rebuild

Post by snopro753 »

Thanks for the unlock. Here is the current progress. Spent a lot of time cleaning parts. I built a parts washer out of Harbor Freight parts and Simple Green cleaner. Works awesome on aluminum dirt bike parts. I will try to update this thread as I go. I need to source different triple clamps to work with the 1997 KX125 forks I have. I need to build or buy a bearing puller for the swingarm and linkage bearings. Will be slow progress but I am excited about this build again. Been 5 years since teardown.
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

Be careful with Simple Green and other alkaline cleaners on aluminum. It can etch the aluminum if left on for a little while.
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Re: My $150 1993 KDX 250 rebuild

Post by snopro753 »

KDXGarage wrote: 12:24 am Jan 14 2020 Be careful with Simple Green and other alkaline cleaners on aluminum. It can etch the aluminum if left on for a little while.
Jason, I researched it and found other dirt bikers using this Simple Green Purple mixed 50/50 with Water in their parts washers. It works really well and the stuff I cleaned last year on a different bike didn't damage the Aluminum.
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Re: My $150 1993 KDX 250 rebuild

Post by snopro753 »

Found a place in England that makes graphics for 1994 KDX tank shrouds like my avatar. Anyone purchased from here before?

https://www.evo-mx.com/shop/kawasaki-kd ... s/trkdx07/
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

OK, watered down is good.

I have read of several on other forums buying from evo mx, all pretty happy. They have been around for a while.

They also have some other sticker kits from around those years.
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Re: My $150 1993 KDX 250 rebuild

Post by bufftester »

An assortment of sockets and a bench vise will take care of your linkage and swingarm bearings, no need for a puller if you already have a vise.
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Re: My $150 1993 KDX 250 rebuild

Post by kdxsully »

Yeah I don’t think the interference fit is that tight on those.
I like turtles
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Re: My $150 1993 KDX 250 rebuild

Post by snopro753 »

Okay, thanks for the heads up. My bench vise should get the job done then.
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

Rocky Mountain is having a tool sale. One of the things is a bearing driver set.
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Re: My $150 1993 KDX 250 rebuild

Post by snopro753 »

Slowly working on this project still... See attached pictures.

I am using the Stock KDX250 stem that pressed nicely into the 1997 KX125 lower clamps. The issue is the 0.040" clearance between the KDX250 stem and the KX125 top clamp. I need to take up the 0.020" gap. Any ideas?
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Re: My $150 1993 KDX 250 rebuild

Post by KDXGarage »

just buy some flat sheet metal and cut out a rectangle and stick it down inside there. I think I bought 0.025" LONG ago to put in there.

If all else fails, ... Coke can. :-)

The Coke can be used to practice on cutting it into a shape you need.
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