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Kawasaki MX & Off-Road Dirt Bikes
Fork Swap: KX80 forks on a KDX80
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[QUOTE="Magellan, post: 1432660, member: 22253"] [b]Done...Finally[/b] Didn't start working on the bike till this spring. Spent the fall and winter collection parts. I stripped it all down and repainted the frame Kawi green and painted the swingarm and pegs silver. I had to have the cylinder re-plated. I probably could have run it as it was, but there was a small nick near one of the parts and the plating was work through in a few spots. Add $360 for re-plating, piston, and rings. Replace all the bearings in the chassis: wheels, swingarm, linkage and shocks. Put the KX 80 front end on it. I ended up picking up some bronze bushings and turning one down on a lathe so I could use the stock KDX80 steering bearing races on the KX80 stem. That was overall pretty straightforward. I also had to mill the nut on for the triple tree (one just above the bearings) a bit so that it would all bolt up and still have enough threads for the final not on the top of the triple tree. I shortened the KX80 forks (these are the damper rod ones) with a 4 inch spacer. The stock KX65 for springs are the same rate as the KDX80 springs and are 4 inches shorter. Picked up a set off flea bay, threw in some new seals, and the front end was almost done. I picked up a '00 wheel, not realizing it was a bit wider than what I needed. I have it working for now, use some inner races from the old wheel bearings as spacers. I'll make some spacers for it later. I had painted the hub and don't feel like doing another wheel. New spacers will be easier. Rebuilt the rear wheel using a KTM 65SX rim and custom spokes from Buchannan. New front Maier fender. I have a Maier fender for a KX80, but again, it is the wrong year and isn't a good fit. I may try to modify it, but for now, the original fender is on the bike. Picked up a good looking used tank off flea bay to complete the plastic. (side panels are orig, but not in bad shape). Cleaned up the carb and treated it to new gaskets. Need some new bars. Came with some ugly blue anodised bars that we're using for now. So, the $250 bike ended up closer to $1800 after all the parts (including new tires). My son rode it for the first time today in the yard. Took him a few tries to get the clutch down, but he loves it. It starts first kick and runs really sweet. I'm in the market for a better rear shock. I think maybe a KX80 shock will work and it would be good if I could add an inch to the back. I have the fork tubes slid up an inch, but the bike could be a bit taller fro my son. I'll post some pics later. [/QUOTE]
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Dirt Bike Discussions By Brand
Kawasaki MX & Off-Road Dirt Bikes
Fork Swap: KX80 forks on a KDX80
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