fork swap on 91 K5

[dirk_411]

Hey guys. I've searched and read some information from the site. 

Question is, what fork set ups are a direct swap onto the 91 chassis? I've read and think I understand that
My 91 front end will swap out with everything up to 04?  Is that accurate?

Also, do any of newer 4 stroke set ups swap direct or with little mods? 

My intention with this bike is to run 20km (one way) to work and if possible have spare wheel and tires to ride dirt when I want, oh and sit on a stand for 5-7 months depending on how long winter is

Answers from experienced members or guys with hands on preferred

[sandblaster]

You can use whatever kx500 front end you want with the corresponding triple, front axle, front brake, and wheel.
With a steering stem from EMIG you can use whatever you want from late model KX's
http://www.emigracing.com/

[dirk_411]

Any year K5 better than the other, or should I look into what motorad did with the kx450 front end

[sandblaster]

If I was going to use K5 forks I would go 97-04.
If I was rolling in the dough I would go as new as I could afford (KX450F or KX250F Valved and sprung for what you weigh and how you ride) with a matching rear shock.

[dirk_411]

I'm actually interested in the kx450f. If you guys don't mind giving me a hand with this I'd like to see this come to fruit.   Something to keep in mind I'm basically an assembler, I do not have the ability to weld or machine. I think it would be an opportunity to see if anyone here could lend there expertise.

This will take time, hope to make this a winter project.

Could you lay down a parts list of what I need to look for. And I agree that I will look for as new as possible. If the 450f don't pan out then I will go the K5 route

[sandblaster]

Once you decide on the year of the forks then a parts list could be made.

[dirk_411]

SB, When starting my search should I base a new front end off the triple clamp assembly or the forks? Best I can tell it will be a part by part endeavor.   

So buy triple clamp or fork first?

[sandblaster]

Forks are the most expensive part so that is where I would start.
But I would consider my budget BEFORE I bought anything.
See what a complete front end would cost for the forks you are considering.
Forks, Stem, Front brake, front wheel, front axle, and triple.

[sandblaster]

Also, if you don't have access to a press, talk to Emig about removing the old stem and pressing in their new one.

[Motorrad]

http://www.kxriders.com/forums/index.php/topic,6712.msg51443.html#msg51443

[dirk_411]

Motorrad, thanks for the link. It is hard for me to understand the numbers when talking offset and so on(not a bike guy, don't understand the adverse effects of steering change on the triple tree set up). Or was the point that Emig  can make me the proper steering stem? Which appears to be the only piece that involves altering to make the swap.

Am I going to run into any other issues if I go 2010 or newer? That you know about?

[dirk_411]

It appears there are more 250f front ends on ebay than 450f! Like a lot. What exactly is the difference between them?

[sandblaster]

Most (Not all) of the 450f's have a larger tube diameter then the 250f's and are set up for a larger rider/bike weight.
Either could be set up to out perform most of our riding abilities.

[dirk_411]

Talk to Gary at emig today. In the new year they are gonna set me up with a new front end and the dog bones. Should be pretty sweet, one stop shopping, they will set the shocks up too. Looks like I'll want to have near $1500 ready. Awesome new year project. Glad I don't have to buy parts off ebay

[sandblaster]

It should be quite the improvement..
Keep us up to date.