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Old 10-27-2007, 04:18 PM   #1
dragoontwo
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Default KX500 43mm USD fork swap

I decided to take the plunge to USD forks, so here goes.....

I got a set from a '96 KX500, and took the clamps to my machinist to make them fit. He ended up using the KLR's steering stem, and made a bushing to fit it to both the bottom, and top clamp. He also welded up some stock, so I could use the ignition lock, and for the gauges. The stock rotor that came on the wheel was .010 out of tolerance, so I got the EBC oversize rotor which is 280mm. The stock rotor is the same size as the KLR's. I replaced the fork seals, and added some seal savers. He also did not include the bar mounts, so I went with universal big bar mounts from Pro Taper, and got the Contour bar in the Raptor ATV bend. I also used the KLR's brake reservoir and hose. I had to buy a caliper, and it didn't come with those things. I also added some Race Tech .46kg springs in the forks.

So far.... LOVE IT! I won't be going much offroad yet(it rained all week here). However, I did take it out and it's so much better than stock. No chance to really test the front brake yet, as I have to bed the new pads to the new rotor, but I can feel how much better it is already.












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Old 10-27-2007, 06:14 PM   #2
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Default Re: KX500 43mm USD fork swap

Now THAT is cool. Let us know how well it works. This is something I could prolly do on the cheap, as my father-in-law has a machine shop at the end of my yard.
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Old 10-27-2007, 07:38 PM   #3
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Default Re: KX500 43mm USD fork swap

Now that's forkin NICE!!!!! Sweet set-up! BTW, where'd ya get the digital speedo??
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Old 10-27-2007, 08:01 PM   #4
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Default Re: KX500 43mm USD fork swap

sorry i missed ur call man.... but damn still jelous of ur bike man. got to get together soon so i can test it out with the new shock in the rear and now the new ones up front.

SHOCKS...PEGS....LUCKYYYYY!!!!!!!!!!!!!!

my inlaws were in for the weekend so i was out and about all weekend but they are gone now so maybe sometime this week u can swing by and check it out. keep it up and i may have to steal the bike and leave u with a red one. great job.
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Old 10-28-2007, 09:42 AM   #5
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Default Re: KX500 43mm USD fork swap

Well done ! Just goes to prove that when there is a will there is a way !
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Old 10-28-2007, 11:31 AM   #6
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Default Re: KX500 43mm USD fork swap

Glad to see another no-windscreen KLRer!

Would you have been able to use the KLR wheel and brake? I'm looking for USD forks and need to know what I'm looking for.
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Old 10-28-2007, 12:00 PM   #7
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Default Re: KX500 43mm USD fork swap

in short, no. the brake bracket won't fit.(the bolt spacing is off by a bit) and the KLR's wheel hub hole is too small. the forks are also a bit narrower.
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Old 10-28-2007, 04:22 PM   #8
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Default Re: KX500 43mm USD fork swap

Man, that looks sano. Beautiful job..

Brian
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Old 10-28-2007, 09:11 PM   #9
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Default Re: KX500 43mm USD fork swap

Nice job! Please give us a report on how it works when you get a chance. Also hydraulic clutch? How about a report on that mod?
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Old 10-29-2007, 09:59 AM   #10
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Default Re: KX500 43mm USD fork swap

Nice bike! I'm curious about the size of the Pelican on the back.
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Old 10-29-2007, 07:56 PM   #11
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Default Re: KX500 43mm USD fork swap

thanks for the compliments. I really wouldn't have been able to have it done so quickly and easily if it weren't for the machinist I work with converting the clamps. feel free to ask more questions about it.

The pelican on the rear is a 1450.

The hydraulic clutch is the magura from dual-star. I like it for the simplicity, and the better clutch pull and feel. It pulls easier than the cable, and is very predictable. It also works with the clutch safety switch if you like.

Spike- unless you plan on going with a digital cluster like I have, you may want to find a set of USD forks that have a speed sensor on them. Probably your best bet to try and find the KLX650 ones. I also loke the no windscreen.
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Old 10-30-2007, 08:42 AM   #12
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Default Re: KX500 43mm USD fork swap

Nice work.

Did you measure offset, travel, rake, trail? Did you use the stock KX 500 fork springs? Basically did the KX fork change the steering geometry? And if so what changed and what is the riding difference?

I am asking because I too have been shopping for used forks and am wondering what how a newer, longer travel stiffer fork will affect geometry. I know the stiffer fork will make cornering and off road more precise, but the rest????

thanks for the write up.
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Old 10-30-2007, 07:19 PM   #13
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Default Re: KX500 43mm USD fork swap

Quote:
Originally Posted by Vtcyclist View Post
Did you measure offset, travel, rake, trail? Did you use the stock KX 500 fork springs? Basically did the KX fork change the steering geometry? And if so what changed and what is the riding difference?
No. I didn't measure any of that. I only changed the forks. the only difference right now on the street is that the front end feels a lot more planted, smooth, and predictable. I haven't done any crazy street stuff, but it soaks up quite a bit that wouldn't have been with the stock forks. Sitting static, the forks seem a bit shorter, as the bike doesn't lean over as far anymore. However, there is less sag in the front. As far as springs, they aren't stock. I used Race Tech .46KG springs.

Less vibe on the highway, more planted/better feel in the turns, less steering head shake(still got the stock fender up there), soaks up sharp hits better(ex. seams on the highway, bridge transitions). After having done it, I don't know why I hadn't done it sooner.


And if anybody is in the area, and wants to give my bike a try, just come on over...
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Old 10-30-2007, 07:41 PM   #14
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Default Re: KX500 43mm USD fork swap

Is that really all there was to the tripple clamp conversion. Bushings for the top and bottom clamp? What about any spacers for the bearings?

Looks great

TW
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Old 10-30-2007, 07:43 PM   #15
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Default Re: KX500 43mm USD fork swap

That's it. Stock KLR shaft, and bearings. 2 bushings for the shaft(1 on top and 1 on bottom), and he milled out an area for the grease seal on the bottom clamp.

Let me say....... I wouldn't go this route if I was using the stock instrument cluster. I had already installed the digital gauges prior to doing this.

Last edited by dragoontwo; 10-30-2007 at 07:46 PM. Reason: added info
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Old 10-30-2007, 09:32 PM   #16
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Default Re: KX500 43mm USD fork swap

Cool mod and relatively simple. I like.

As for the guages, seems there are some very nice alternatives like the Veypor.

The brake mod looks like a pretty healthy bracket too.

TW
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Old 09-25-2008, 09:52 PM   #17
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Default Re: KX500 43mm USD fork swap

That is Awesome! I was thinking about KLX 650 forks for mine. What was the final price tag on the forks installed.
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Old 09-27-2008, 10:29 AM   #18
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Default Re: KX500 43mm USD fork swap

Welcome to the USD club. You will love the feel of the front end. I went with a KTM 250sx set of WP forks. I used the stock KLR wheel, then grafted on Brembo brakes from a newer Husaberg. One finger braking.



It took a bunch more machining than yours did, but I have my own shop.

Now, to make the package a total deal, send me your rear shock and I will send it back looking like this :



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Old 09-28-2008, 04:05 PM   #19
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Default Re: KX500 43mm USD fork swap

Didn't think anyone would dig this thread up.....

I did it almost a year ago, and I still love it. Went out this weekend and really used it. They don't bottom out like the stockers I had did. PorscheScum, I have the moab shock and the shaft on my stock one is nicely blue and purple...

As far as cost, I don't remember an exact price, but I did add a lot of add ons at the same time, and I think it totals out around $1000 with add ons.
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Last edited by dragoontwo; 09-28-2008 at 04:06 PM.
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Old 09-16-2010, 09:16 AM   #20
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Default Re: KX500 43mm USD fork swap

The conversion looks awesome Hopefully mine will look and perform as well.

I'm going to be sending my tubes out to a friend of mine at Watermagicimagining.com for a Carbon Fiber film dip. It should give the forks a cool look and maintain the Black and green paint scheme
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