front end delima! ahhhhhhh

[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!

[The Flyin Hawaiian]

Oh ok, I thought you got the forks also.

[Friar-Tuck]

 Here's what it looks like for seal/oil service.
 If I understand you correctly the spring guide snapped.  This is all the farther you need to go if the valve is still good.
  Part 1
    http://www.youtube.com/watch?v=Y43k1qFVGW4&playnext_from=TL&videos=1BTv6C9XHdo
Part 2
http://www.youtube.com/watch?v=C9ICr-DOmdk&feature=related

 
 If you need to replace the valve also you'll need these also
  Damper rod fork tool
http://www.motionpro.com/motorcycle/partno/08-0117/

14mm hex (1/2 or 3/8 drive)
http://www.craftsman.com/shc/s/p_10155_12602_00942669000P?vName=Tools+%26+Equipment&keyword=14mm+allen&prdNo=1&blockNo=1&blockType=L1

  Tuck\o/

[don46]

you can adapt forks from a newer bike pretty easily if you have the right tools, for me, if I was to change I would go with something that is the newest technology, but thats me. most of the 250s have a larger top stem bearing, bottoms are the same. You can press the stem out of the 500 clamp and press into a 250 set of clamps, you'll have to make a bushing for the top clamp as it will be a larger diameter and maybe a small spacer between the clamp and the bearing jam nut so your number plate fits properly.

You can also go the easy way and call Emig racing and have them make you a stem, you'll still need the bushing for the newer clamp.

[BDI]

You know one cool thing about stuff like this is when you get the wrong part you can just put it right back on ebay and get your money back. I have had stuff resell for more then I bought it for. I agree with don on the buying the newest stuff you can get your hands on. Very nice forks can be had for 3 to 4 houndred and the latest and greatest forks for 6 to 7 houndred. I have 03 forks on my my 02 kx250 chassis by just pressing the right stem into the clamp. You have to do your research for stuff like this.

[crazyolbastard]

First off thanks all for the advise and help.
The guy I bought the forks from will let me return them and give me my money back.
The video is very helpful-  thanks alot Tuck.
I`m going to replace the dampner rod that fell out and into the spring and locked up the valve.
Other than that all I need is the piston retaining half clips and seals and I`ll be back in the dirt.

Will black tape work as a seal bullet?

[DoldGuy]

Crazy O B,

Go into the kitchen & spool off about 2' of the little ladies wax paper. Use it as your seal bullet to cover BOTH edges where your bushing goes. Apply some grease on the wax paper & on your inner part of the seal & dust seal, they will slide right on with no tears. Plus you don't have to clean a seal bullet when done

DoldGuy

[crazyolbastard]

that`s usin it for more that a hat rack.

great tip D

[meangreen500]

a plastic zip lock works too. put grease on and slip it over.

[ktmdude]

I have used the bag that the seals come in with a little fork oil, works fine. Samwitch bags work well also. I did a over hall on the girlfriends dads forks and he gave me a bullet, so I have one now. It is a bit nicer but not nessary.

[crazyolbastard]

got all the parts I need and the seal driver, all the parts that is except the bushing kit.
anyways, I threw the forks back together cuz I am jonesin`
I need to ride.  I need to ride now!
thanks for all the tips guys.
the bushin kit is on backorder at cheap cycle parts til the 27th of July.
til then let them leak a lil oil.
I know where the car wash is.