KX500 - 2006 CR250 Forks and Triple Clamps

Forks, shocks, linkage
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Pile-O-K5
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KX500 - 2006 CR250 Forks and Triple Clamps

Post by Pile-O-K5 » Fri Jul 10, 2020 8:08 am

I have a '94 KX500 and wanted to upgrade the suspension.

I came across the all balls racing conversion chart located here:
https://www.allballsracing.com/forkconversion
Most CR's seem to fit. The chart does not consider swapping steering stems.

Conveniently, a riding buddy of mine has a '97 CR250, so we began taking measurements. The steering stems seemed to measure out ok, and the all balls conversion chart lists the CR250 as a potential swap. The chart also includes CR/CRF's/CRFX out to '18. RM's and RMZ's also fit out to '18. I have a KDX220 that I will be trying a RMZ conversion on later this year. Will post the results here since it should be similar to the 500 for fitment.

I came across a good condition 2006 CR250 fork and triple clamp setup for relatively cheap and is a good enough upgrade for me and the riding I do. The swap will also require the use of the CR wheel and brake.

I bought the conversion kits from all balls for the upper and lower steering stem. Here is what came in the box; each box contained the bearing and cup required for the swap, dust seal and 2 washers of different diameters and depths. Good stuff, 3 of the 4 washers in the two kits are not needed.

What's in the box?
Image

This swap is/was relatively drama free. One of the washers from the conversion kits is the correct depth for the upper bearing race. It is needed as the supplied bearing is 3 mm less wide than OEM. However the washer needed to be modified as follows, the inner diameter needed to be increased to allow the bearing to seat into the cup properly and the outer diameter needed to be decreased to allow the washer to fit into the steering race. In addition a steering stop needs to be created. My solution is to weld on additional material to the original stop tab and frame and engage the tabs on the lower triple clamp. I have it drawn up in CAD.

Fit AND Finish:

Image

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CAD:

Image
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I am not quite finished yet the swap yet. I am waiting on a brake rotor and need to pick a machine shop to create the steering stop.

I will post some pictures to show the nut engagement on the triple and how the fitment looks. I couldn't be happier with how it fits.

P.S.

I am grateful for the information on this site. Helps me keep my bike going, and improving it.
Last edited by Pile-O-K5 on Sat Jul 11, 2020 12:59 am, edited 1 time in total.

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Sandblaster
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Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Sandblaster » Fri Jul 10, 2020 2:53 pm

Excellent.
I've been aware of the All balls kits for a while but never tried them.
Post pics when you can,
Thanks
If bikes are for kids I'll never grow up.

Pile-O-K5
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Joined: Wed Jun 03, 2020 1:52 am

Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Pile-O-K5 » Sat Jul 11, 2020 1:00 am

Original post updated with pictures.

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Sandblaster
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Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Sandblaster » Sat Jul 11, 2020 4:03 am

Very nice.
Those forks should make a nice improvement.
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Sandblaster » Sat Jul 11, 2020 4:20 am

You could buy this...


conversion.jpg
conversion.jpg (129.95 KiB) Viewed 237 times


On some of the triples the angle is Alex Ward little off but works fine.
Or you can grind and polish to your preference.
If bikes are for kids I'll never grow up.

Pile-O-K5
Posts: 5
Joined: Wed Jun 03, 2020 1:52 am

Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Pile-O-K5 » Sat Jul 11, 2020 5:25 am

Thanks for recommending that. I did not know something like that exists. :mrgreen:

Pile-O-K5
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Joined: Wed Jun 03, 2020 1:52 am

Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Pile-O-K5 » Sun Aug 02, 2020 2:00 am

Progress.

I tried the trick engineering steering stop, it needs to be modified significantly, but useable. The bottom triple clamp needed a slight modification as well so that the bottom number plate mount did not interfere with the steering stop.

The steering stop and the triple clamp as it came:

Image

I had to flip the steering stop over so that it cleared the nipple for front number plate for test fitting.

Modified steering stop and number plate mount:

Image

Image

I decided on about 1/4" - 5/16" clearance from the fork tube hitting the radiator cap. I may take more material off the steering stop after a couple of rides. Maybe take enough material of the steering stop to close the gap up to 3/16" or so.

The nipple on the bottom triple clamp for the front number plate can be cut down to clear the steering stop. It allows the front number plate to engage the nipple with enough material to not be an issue. The bolt for the number plate is at the top and essentially locks it in.

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Sandblaster
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Re: KX500 - 2006 CR250 Forks and Triple Clamps

Post by Sandblaster » Sun Aug 02, 2020 3:36 am

Good to know.
Be sure to update us after you ride it. 8-)
If bikes are for kids I'll never grow up.

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