Author Topic: 2009 KXF 250 forks on 04 KX 250  (Read 5874 times)

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Offline umberto

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2009 KXF 250 forks on 04 KX 250
« on: May 26, 2016, 11:56:44 AM »
I am having Stillwell performance do a re-valve and coat on the front forks for my 2004 KX 250.  The fork and shock came off a 2007 KX 250, and work pretty well on my 04.  In order to coat the lower forks they have to remove the lugs, which ruins the threads.  Unfortunately, the lugs can not be purchased separately like the later (08 and up  :x) years.  I got to thinking that it might make more sense to buy a set of KXF forks that are from a later model bike (which come with the coating) and use them instead.  Stillwell thought of this as well, and said that the newer forks offset is 32.6 mm versus the 38.2 mm on my forks and may affect the handling adversely.  I know Motoradd has tried the KLX forks on his 500 with pretty solid results, but has anyone tried to mount the later 250 or 450 forks on their 03-04 250s?  I would not be opposed to using the triples from the KXF, if someone had luck with using them and the forks as well.  

I have some time to research and think before he has to have an answer.  It's not like I'm going anywhere with a torn rotator cuff anyway.   :-D

Thank you for the help guys!
« Last Edit: May 16, 2017, 08:46:43 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144

Offline treedodgingfool

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Re: KXF forks on 04 KX 250
« Reply #1 on: May 27, 2016, 02:11:56 AM »
Personally, I wouldn't play with the off-set on the '04 KX250. It is literally one of the best combination of handling characteristics on an MX bike/off-road bike I've ever ridden and I used to sell them (and have ridden a bunch on top of that). I wouldn't mess with it just to get a DLC fork coating, even as cool as it looks (I doubt there would be a major improvement in fork feel, not enough to off-set the off-set). I'd say if you're not a 100% happy with your suspension action, even giving the concession for varied conditions in the same race/day and the compromise off-road we have to balance (like riding South Jersey sand & hardpack, or New England rocks & sand, etc), I'd possibly look into a different suspension guy, preferably one closer to you with a lot of experience in the regional terrain you generally ride or race if your not 100% happy with the valving.

On my own '04, I have tried a mired of suspension combos over the years, my current favorite for my application on my '04 KX300bb I race/ride east coast off-road with in the A class is a WER revalved '03 KX250 forks & a WER revalved '07 KX250 shock. The forks have SKF seals, are serviced (along with the shock) at least once a year or more. This combo has been a phenomenal set-up for me off-road, plush enough to eat trail junk & still go straight through the whoops and enough adjustment to be super compliant in the rocks to boot. I also use Flexx bars & a WER dampner which are the icing on the cake.
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Offline KXDINO

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Re: KXF forks on 04 KX 250
« Reply #2 on: May 27, 2016, 09:01:36 AM »
it shouldnt damage the threads on the lugs if you heat them up first plus you must loosen the lock grub screw on the inside of the lug , you might have to gear up on some new tools or get one of the suspension shop to do it for you , they put some form of locking compound on the threads hence the heat to melt it a bit ,easy.

Offline KXDINO

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Re: KXF forks on 04 KX 250
« Reply #3 on: May 27, 2016, 09:18:41 AM »
when i was at race tech many years ago they had a box full of fork lugs with different off set for mx bikes changing over to motard wheels as you have to change this to correct the trail , so it only a matter of machining a new set up , but if your carefull you should be able to save the oem ones.

Offline umberto

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Re: KXF forks on 04 KX 250
« Reply #4 on: September 09, 2016, 09:18:34 AM »
I know you guys warned me not to, but I got a really great deal on a set of 09 KX 250F forks.  I did some measuring, and the forks ended up being about 1/2" longer than the 07 forks.  I initially tried the stock 09 23.5 mm offset clamps without raising them in the clamp, and that was a train wreck.  It handled like a chopper.  I then bought a cheap pair of stock 08 24.5 mm offset clamps off eBay and raised the forks 1/2" in the clamps, and the handling improved a ton.  It was close to the 07 forks, but I still wasn't completely satisfied.  I found a set of Applied Racing 25 mm offset clamps on BTOSports.com that were very economical and the bike was right back to where I started handling wise.  It really turns nicely.  Stillwell offered to lower the forks 1/2" if I send them in for service, but otherwise I am very satisfied and they look pretty trick.



Anyway, I figured I would post in case any one had a set lying around and wanted to try to mount them on an earlier KX.  The 08 stock clamps with the forks raised 1/2" was pretty close to stock if you don't want to use aftermarket clamps.
« Last Edit: January 06, 2018, 02:15:50 AM by umberto »
Perhaps I have a dirt bike addiction?

03 KX 250/88 KX 525/2017 KX250F - Goliath
17 KX250F/04 KX250
04 KX 250 - Lunchbox's Bike
05 KX 125/144