KMX 200 - fork change

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Hi all,

Does anybody know if a KDX 200 fork and yoke will go straight onto a KMX 200 ?

I've been told the KDX125 front end fits, with a change of head races.

Thanks
Dave
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

RPM · Nova Slayer Joined: 16 Apr 2011 Karma :

Hello

I am sure that the forks will fit relatively easily. I have previously put KDX 200 forks onto a KMX 125. IMO this is a good upgrade, the front end felt much more solid, with better braking.

The only issue I found was the reduced turning circle, although it was nothing that a grinder couldn't resolve. I made a couple of V grooves in the lower brace (aligned with the frame stops) to increase the turning circle, passed the MOT without any problems etc.

iirc you might have to make another bracket to mount your clocks or at least I had to do so.

All the best
Mike

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Excellent - good to hear from somebody else who has done it.

Yes, I heard the kdx 200 forks were a big improvement on the Kmx items. And the advantage of a better front brake.

Did you have to change the headstock bearings (kdx 200 items) ?

Did you use a kdx 200 front wheel too ?

Thanks
Dave
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

RPM · Nova Slayer Joined: 16 Apr 2011 Karma :

Hello

IIRC I did change the bearings (i think they were a slightly different shape).

I used the KDX wheel mainly for the ease of connecting the original KMX speedo meaning that I could retain the original speedo and recorded mileage.

I can't remember whether the wheel mounted speedo drives were different or not. In my case the KDX wheel was in a better condition than my KMX one, which had started to rust from the inside.

All the best
Mike

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

That's really helpful.

My KMX hasn't got the standard headlamp set up, it's an Acerbis unit which is zip-tied to the fork legs, so that will be fine. No clocks either, just fitted with a digital speedo which picks up off the wheel.

Did you find the kdx fork it changed the geometry of the bike at all - Are the kdx forks slightly longer ?

Did they have more adjustment (compression/rebound damping)

I guess using the kdx fork and wheel enabled you to use the kdx caliper. The front brake on mine doesn't have much power.

Thanks
Dave
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

RPM · Nova Slayer Joined: 16 Apr 2011 Karma :

Hello

The forks are slightly longer but I didn't mind the slight change in geometry, although you could just lower them in the yolks. Don't forget that the fork legs are about four inches longer but the majority of this length is lower than the point where they fix onto the spindle so the effect on geometry is actually minimal.

They have much better adjustment possibilities but mine were fine as they were. The most noticable differences related to the sense and feeling of a much stronger front end which, in my case did inspire confidence, helped by the advantage of superior braking capabilities.

I used the KDX caliper (twin pot) the difference in braking ability was immediately noticable. I personally think that this is probably one of the best upgrades that can be made to a KMX.

All the best
Mike

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Thats some good info there, thanks.

Did you make any other mods to your KMX ?
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

RPM · Nova Slayer Joined: 16 Apr 2011 Karma :

Hello

The only other thing that I did was to fit a Big One expansion chamber.
I also fitted a softer spring in the power valve to help ensure that it was able to fully open (I don't know whether this was actually necessary on my bike) because it was pretty lively before I did this.

I did think about fitting the KDX swing arm onto it, iirc it was bigger but lighter and less likely to rust from the inside, but didn't get around to doing it.

All the best
Mike

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

I wouldn't mind seeing any pics of the KDX front end fitted to a KMX, if you have them?

I can definately see an advantage in terms of suspension quality, and travel for off road use. My bike is going to be a motard, and although it will become a bit lower with 17" rims, i think the 38mm KMX200 forks can be re-worked enough to be ok for road use and the 230mm of travel is probably better than going for longer travel USD forks. It should be easy enough to fit a decent fork brace, and the KLE500 front disc looks to be a straight fit onto the KMX hub. I think the KLE disc is about 300mm so with either a KLE caliper or a 4pot fitted with a spacer it should do a good job of braking a 100kg motorcycle.

As for changing out the KMX200 swingarm, i think it's alot of work, when it's the shock itself that isn't up to much in terms of suspension quality and damping. The KMX200 has a lighter alloy swingarm unlike the 125's so it should be far less likely to corrode, though it's possible.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Hi Mike,

I took the front end out of the KMX to take some measurements of the headstock and look at the bearing sizes.

I got hold of a KDX 250 front end, however this has a much bigger bearing on the bottom of the yoke - 55mm instead of the 51mm taper roller bearing fitted to my KMX.

I have a set of KX 500 bearings to hand (as that is what the yokes are) which are the correct size for the KDX 250 front end, but as above, the bottom bearing is far to big to sit inside the head tube of the KMX.

It seems when you fitted the KDX200 forks the bearings were easily interchangable - were they ball races or the taper roller bearings which you used ?

i'm realising that trying to fit these later USD forks to the KMX isn't an easy conversion with the parts I have to hand, and would probably have been better off going for the KDX200 ones as advised ! Live and learn .. . .

Thanks
Dave
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

RPM · Nova Slayer Joined: 16 Apr 2011 Karma :

Hi

Sorry for missing this. I guess you must be pretty pissed off after all the trouble you have gone to with your conversion.

I also had the chance to use a set of used USD's but didn't do so. I wasn't sure what they had come from and how much messing around might have been necessary.
Plus I kept in mind that my reason for converting was mainly to gain better braking and a more solid feeling front end.

When I did mine the bearings were tapered and iirc the existing ones in both bikes were exactly the same size and fit.

I chose to buy new KDX bearings, purely for peace of mind.

All the best
Mike

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Hi Mike. No probs at all. Appreciate your help Thumbs Up

To be honest I was a bit frustrated when the job wasn't going as smoothly as I've liked - but when does anything ? The forks have gone back in the shed for a while but i've seen others do it so figure it must be possible.

So today I rang the Kawasaki dealer. One of the guys had done the USD conversion on his KMX with good results and has been giving me advice along the way. Where I've gone wrong is assuming the KX bearings would fit the KMX frame (which they don't - they're bigger).

What he did with his conversion was to contact a bearing supplier with the dimensions of the headstock, and dimensions of the steering stem, to find bearings which would fit.

I had a quick chat with somebody from Koyo bearings today & will ring them back when i have the complete dimensions they need.
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

jakeus · Derestricted Danger Joined: 24 Aug 2010 Karma :

[img][/img]Hi Dave.

Water pump broke yesterday on second proper ride.

The nut attaching the impeller sheered.

Looking at a spare,the drive shaft looks pressed in with the bearing?.Is it easier to swap clutch casings or can the drive shaft be removed?.Don't have manual handy!...Anyones help would be very helpfull.

How's your bike going ?.

Cheers Jake

ps... I really do like these kx forks on !.definate off & on road improvement.
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jakeus

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Hey Mike,

What year KDX 200 front end did you put on out of interest ?

If it had the dual-piston caliper then i'm guessing they must have been 92, 93, 94 ish ?

Pretty sure 89-91 had the single piston

Cheers
Dave
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50