91 kx250(front fork upgrade -46mm) Help!

[RonnieMac]

Hey all,

So I bought this 91 kx250 for a project.  The last owner has swapped in some 46mm forks from a 96.  Now they have changed the upper triple clamp but have just stretched the lower clamp to fit.  I would.like to try and find a lower clamp from any bike that would work that would fit these large forks better.  Any help is sincerely appreciated.

[sandblaster]

Oh yeah, that 91 had a lower clamping diameter of 56.6mm.
The 96 used a lower clamping diameter of 58.9mm.

The nice thing is the lower bearing was the same for many years, makes, and models:
FITS 92-05 KX125, 92-07 KX250, 93-96 KLX650R KLX650C, 95-06 KDX200, 97-05 KDX220, 91-94 KDX250, 94-96 KLX250, 06-07 09 10 KLX250S

So it stands to reason that you could use a lot of different lower clamps.
96-01 KX250 all had the same lower clamping diameter..
Mu "Guess" is you could use any one of them.
Give it some time and I'm sure others who have tried it will chime in..

[RonnieMac]

Well that's some good new.  So I guess I could just use a 96-01 lower clamp?  Is the od and inner diameter the same on the bearing? Only thing I guess I need to figure out is how I'll mount the front plate since 96+ doesn't have the holes to mount that yr plate.  Before I go out and order, hopefully some others will confirm this.

[umberto]

I have some non-stock forks on my 2003 KX250/500, and I used the stem from the 2003 to put in a set of 2001 clamps.  The stem is the same diameter where it goes into the bottom clamp, it's just longer on the 2003.  You should be able to press your stem out and put it in the 2003 and up clamps, which allows you to go to 48 mm forks, and opens up a whole world of possibilities.  The process of pressing out a stem is very simple, and just requires a few tools.  I think a machine shop wouldn't charge you much either if you don't want to do it yourself. 

Here's a good video on how to do it if you want to do it yourself.

https://www.youtube.com/watch?v=2R92wxhc4_E

[RonnieMac]

Well, got a 96 lower triple on the way from eBay.  I'll let you know how it goes