06 KDX 200 Fork Rebuild with Gold Valves

Detailed video on rebuilding the front forks on a 06 KDX 200, but these concepts will work on many other bikes as well. I give a lot of tips and tricks in the video and also put in aftermarket fork valving. This is not a suspension tuning video, just a how-to for rebuilding conventional cartridge forks.

[@nickmollison8608]

Using a length of hose to pull the damper rod up through the spring was the exact stroke of genius I needed today. I love little tricks like that and it came in clutch! Thank you for taking the time to document and share your process, all of it was extremely helpful. Keep these great bikes on the trail!

[@PremixandPedals]

Thank you so much for making this video!!! Every video that came up when I searched was for the newer style inverted forks!

[@rminvest6276]

Really appreciate this video. I watched it several times and just completed a refresh on my 2006 KDX front end, including the forks, as well as the steering bearings, etc. I did not upgrade the valve (kept stock spring and valve, which I really like due to the slow technical riding we do), but I did Cerakote the triple clamps and the bottom fork tubes. Thanks again. Well done.

[@Zeeos27]

You have helped me a lot with this video, without your help it would have been difficult for me to understand how that special tool had to be, I am going to share it in a local kdx 200 facebook group, thank you very much! Greetings from Argentina

[@SuperPowerstroke00]

This gave me the confidence boost to do the job on my own. Thanks!

[@XXXCRSPL]

You can leave fork tube in vise and use a floor jack to compress to break the lock nut loose works well also

[@suzyamerica4679]

Thank you for posting this. My bike had its front suspension rebuilt to carry a chainsaw up front most of the time (0.35 to 0.42 springs) and wow, the ride is crazy harsh without the saw. Wanted to see how you would switch out the springs for the originals and/or change the length of that preload tube. Now I'm wondering if you even need to remove any fluid to do the bit with changing springs.

[@carloslocatelli8592]

Thanks. I live in Brazil. Very nice.

[@Dirt-Tomfoolery]

Is there a way to replace the seals without taking apart all the other stuff specifically the damping rod with your special tool.

[@Keeg02.]

At 13:26, what size is the nut used to hold everything in place?

[@prairiedog879]

I’m doing this same job. Sent my valves to Jeff Fredette and he sent them back with settings using new race tech .42 springs.
100mm 7w oil and stock preload. My question is how to figure preload on these forks and also stock preload is over 3cm which is way over common Mx preload. Any insight?

[@dirtbikeprojectchannel9143]

I'm sorry, I didn't notice this comment and I know it's been a while since you posted it. You're probably done with the job already. The spring preload does not equal fork sag. Preload is put on the spring to achieve the right sag. Sag is how much the forks compress when you ride the bike. I'd go with what they recommend to start out with and adjust from there. I'm sure you could also call them up and ask and they would probably have a better answer than I would since it's their product.
The video itself isn't really about the tuning, just how to take the forks apart and get them back together again. I'm no expert suspension tuner, but it sure is fun to learn. There's some good information on kdxrider.net if you have not been there yet, it's a whole forum dedicated to the kdx bikes. I also own the race tech suspension bible book and it's been so helpful to learn about what all the measurements mean and do. I recommend that if you're wanting to really learn how your suspension works. There's no way I can compress all that knowledge into one video or comment.

[@Mattb2606]

Are those forks the same as a 1986 kdx200?

[@prairiedog879]

Putting gold valves in my kdx forks. I sent my base valves to J Fredette