UPDATING KX500 SUSPENSION.

[Sandblaster]

Hello.
That bearing not being pressed in is because it won't fit.
But here is the info you need.
You can use 06-15 KX450F front forks if you use the 97-04 KX500 triple tree..
You can bolt them right up from at least 1988-04 KX500 frames.
You can use the 04-05 and 2013-2015 250f forks also with the 97-04 KX500 triple tree.
If you use the 06-12 250f forks then you will need to make 1mm shims for the fork tubes.

Shocks... The easiest thing to do is use a 97-04 KX500 rear shock and get it valved and sprung for your weight and riding ability.
The issue is the shock reservoir on the 4T bikes hits the pipe.
It is possible to do a remote reservoir but I have not found the good setup yet.

[Sandblaster]

So Adam Millar and I were talking the other night.
He has a customer in the UK that want's a KX450F rear shock in his KX500.
I send Adam the info showing that the reservoir hits the pipe.
I told him that I was thinking about doing a remote reservoir.
He said, why not cut the reservoir off, and reuse it.... Doy
So, a little cutting and welding, some fittings and some braided lines and we will see what we have...

[Motox306]

so i have a 1993 kx500 and was wondering what i could do with mine with the front, i have 1998 kx250 steering stem, clamps and forks. what can i do with my 1993?

[Sandblaster]

If you have the 97-04 KX500 triple clamps then the world is your oyster..
You can install 06-16 KX450F forks right in.
You can even use the 2013 YZ450F forks

[Motox306]

so all i need are the triple clamps, the stem from the 93 will work

[Sandblaster]

You need the complete triple tree, steering stem and crown (Upper and lower part) 97-04 KX500, and the corresponding front brake caliper, brake mount, axle, axle spacers, and wheel, for whatever forks you buy.

[Jchristopher]

I posted on your video as well, but if you have access to a 2010-2013 yz450f shock that might be one to try since the reservoir is perpendicular to the shock body. The boot would have to be modified to run under I believe, but it may be something to look in to.

[Sandblaster]

Good idea.
I look at every shock that comes in
Unfortunately we don't get a lot of newer bikes like we use to.
It use to be very common to get bike 5 years and older.
Now it seems they are at least 10 years old and older.
That's what happens when so many riders are out of work, under employed, or booted from the work force.
They hang onto their bikes longer which I completely understand.

On a side note, we rebuilt Sean Colliers bike and he said the suspension works as well as anything he has ever rode.
So, getting the stock KX500 shock rebuilt with quality components, springing it, and valving it to your weight and riding level will go a long way to getting you what you need.

Thanks again for posting.

[Zerofear66]

If you have the 97-04 KX500 triple clamps then the world is your oyster..
You can install 06-16 KX450F forks right in.
You can even use the 2013 YZ450F forks

Quick question

Is the 2013 YZ450 fork the only year that will slide right into a 97 and later triple clamp? For those who have ridden with that SSS fork....its unbelievable when set up right! P L U S H!!
TIA!!!

[Sandblaster]

Generally speaking, the Chrome diameter follows the outside clamping diameters.
IF that is true, the seals for the chrome tube 17D-23145-00-00 fit 2010-2016 YZ250F and YZ450F so it stands to reason that 10-16 would all bolt right up.
However, the only year I have actually measured is the 2013's and... the 2006 YZ450F.
What you need is something close to the following: UPPER 53.8MM - LOWER 58.9MM
The 2006 UPPER 55.82MM - LOWER 59.06
Or, .080" difference between the upper KX500 and the 06 YZ450F forks
The lower is .006" difference.

If anybody has some of the in between years please feel free to share your clamping diameters.