Maintenance & Technical > KX500 Original

front end delima! ahhhhhhh

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crazyolbastard:
okay, here goes.
I own a 91 kx500.
The person I got the bike from said it had a 96 front end on it.
The right fork has severs valve problems.
No cheap fix I know of.

I got a set of tripple clamps off e-bay for a 2003-2007 kx250 with my fingers crossed.
That backfired.
Not even close.
Larger top steering bearing, largere fork clamp area then I stopped looking.

So, I see a set of forks for a 96 250 on craiglist.
150 buck.  Got em.
Went to bolt them on without measuring.
Backfire.
.08 inches bigger are the 250 forks.

I wanna shoot myself.
Any ideas?

The Flyin Hawaiian:
If the lower steering head bearing is the same as the 500, you could press the 500 stem into the 250 lower clamp. Then you can use the 500 upper bearing.

crazyolbastard:
but the forks won`t fit the trip clamp.

Friar-Tuck:
 Hey crazy, I just went through a set of '93 250 forks, (seals wiper & fluid change)  one fork seemed to be wasted and was only a $22.oo inner fork rod broken.   seals, oil, wiper and inner rod was only about $100.00.  (yea labor was free)
   You might want to dis-assemble the forks and see exactly what's up.  Before you spend any more $'s.
You got the engine figured out, the suspension is really not any more complicated.. I know it's not the same as a newer suspension, however getting the present set-up re-sprung and valved for you might be the least expensive option.

  Maybe some of the other guys who have had their suspension re-built and re-valved (tuned for them) will chime in.

 Tuck\o/

crazyolbastard:
Great advise.
The upper dampner assm was busted in 2. half was stuck in the spring and the rest made it`s way all the way to the under side of the spring jammin up the valve.
It took me and a young guy to pull it apart.
Funny thing is I have the smarts of the bunch.   ;)

Yup,  parts about 120 includes a seal driver.
Thanks Tuck!

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