Ive decided on the klx650 forks for this project for several reasons. The main being: cost, availability and ease of fitting.

They cost me $250 with the axle and triple clamps. These are not as sought after as the wr or cr forks so can be easily found. the wreckers I found had 5 sets in stock, so they arent a big seller. (I ended up buying 2 sets, so I have an extra pair for future projects etc).

The upper and lower bearings bolted straight in, so no bearing swapping.
the stem was almost the correct length, a little shaving of the reataining nut will get around this.

some mods to consider will be this:
1: the xtx axle was thicker so one fork leg will need to be drilled and tapped so the axle screws into it correctly.
2: I'll have to make up a plate to fit the black 4pot brembo caliper to the fork leg, no big problem as it kind-of lines up ok. (will post pics later).
3: a tang will need to be welded to the frame for the steering stops.
4: I'll make up a plate for the steering lock/ignition (hopefully lock will still work ok).

I'm sure the KLX forks will be more suited to the weight of the XTX so hope she will handle ok with these forks.
I'll add more pics of the project as I go.
any comments welcome!

Really nice how about the steering stop?

Skickat fr�n min GT-I9100 via Tapatalk 2

sorry for the late reply.

Im just doing the job at the moment.
I made up a 5mm thick alloy plate for the ignition lock and a plate for the disc mount.
everythings going well with hardly any mods. bearings etc fitted perfectly.
the kawasaki forks are about 3" longer, so I've sat them higher through the clamps.

I will have to weld a small piece of solid steel for a steering stop that will be at the front of the lower bearing holder.

I shaved about 3mm off the ignition lock bracket thats welded to the frame so as to clear the ignition lock bracket I made.

steering lock still works fine.

I had to belt the bracket I shaved down a little bit as the handle bar mount nuts were rubbing on it.

I have 2 XTX's so will compare the handling over stock suspension soon as shes back on the road.

will post pics in the next couple of days of the completed project...

heres some pics:
I still have to belt the bracket in a bit more as the steering lock tag is still rubbing on the handle bar mount nuts...

the bars are a little bit higher due to the risers/bars so the clutch cable is a bit short.

the caliper mount was easily made and fitted well. It's only a template at the moment so I'll make a thicker one after I get the rim fitted to the hub.

The steering stopper will have to be welded roughly where the masking take is here:

I forgot to mention 2 holes needed to be drilled for the allan bolts on the lower clamp so the headlight bracket could slip over them. Also the axle hole on the KLX is smaller than the XTX axle (only the threaded end). I had to have the fork (caliper mount side) re-threaded to fit the xt axle. the width was the same and the other fork side was the same so no real problem there...
Ill upload more pics as I go.

Blimey looks good!!! How much thicker are these forks compared to the standard XTX??

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(Now sold on, sob) 2011 Blue XT660X with gold wheels, was 26,500 km.
Engine mods: K&N Stage 1 filter, DNA Stage 2 filter, snorkel removed, Kev fuel mod fitted.
Plus: smoked Puig screen, Yam aluminium sump guard, Yamaha / Acerbis handguards, Givi Trekker aluminium side cases, Leo Vince X3 cans plus Kev front fork mod and Fender Xtender. Just fitted Michelin Road Pilot 3 tyres.

SOLD the XTX for a Super Ten 1200. And just bought a Raptor 700 so staying on here for some tips....

hi Simon, mate the forks are the same diameter as the XTX (43mm). I really dont think these will be any better than the standard forks on road as a motard but maybe ok for more bumpy riding on the dirt. This swap may be better for the XTR rather than the XTX... in my opinion.

it's all I had to work with at the time and at $250 were cheaper than buying new fork tubes to replace the bent ones I had on the original forks...

finally finished, well nearly! just need to fit the single akra and make up some header pipes... this wont be for another month as I'll be overseas till then. will keep you guys updated on the actual handling. all up the front end is 1.5" higher with the forks dropped down the way I have them (1.5" above the top triple clamp). All up the only machining I had to get done (apart from making up the 2 alloy plates), was getting the fork leg drilled and threaded to fit the xt axle...

hope this info helps anyone else looking into doing a fork swap...

the end product:

Cracking job Hypoboang and good write up too!

*types this while checking UK eBay for KLX forks*

B*gger - none in the UK. Clearly another bike not sold here or sold in very low volume

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Keyboard Adventurer

Honda CR250 forks are a bolt in fit... yer can find them almost everywhere..
just need a top bearing & the XT bottom bearing.... steering stops are easy to set up..

The XT's look good with a set of USD's..nice job....

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Harley Davidson..
The easyest way to turn gasoline into noise with out the side efect of horse power...

Petenz - I did the same search after watching your thread. However, in the UK both the CR and KLX are not common. The most common off-road affordable forks are of the YZ variety followed by KTM's [WP] that are not so affordable.

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Keyboard Adventurer