I did this work for my KDX, and posted it on the KDX forum, but the general info can be used for the KLX as well. Thought some of you might find it helpful. Check out the Kouba site for a description of the different links for KDX/KLX
I'm only 5'7"/155lbs.
The rear suspension, aside from the bike being too tall, is also too stiff for my liking.
I knew nothing about lowering links, so I read up on the Koubalink site, thought it looked like the ideal solution to my problem, and bought a set of the KDX 1 links. I really wanted the KDX 2's, but the guy I bought them from convinced me that the 1 would be better.
After installation, the rear dropped about an inch, and without making any adjustments, felt plusher, and more comfortable right away. I haven't done any high speed riding yet, but on my property, I can definitely feel the difference. This got me thinking. If the 1's were good, the 2's must be better :razz:
I'm too cheap to spend the money, so I took a few measurements, and made up a few sets to experiment with. They aren't fancy, but when I settle on one, I'll radius the ends, drill some lightening holes, and fancy them up a bit.
The stock link has a center to center distance of 112.5 mm. You can see this conveniently stamped on the side. The KdX 1 link has a cd of 118 mm. I contacted a guy on Thumpertalk who has a set of KDX 3 links, and he measured a cd of 124 mm. As you increase the center to center distance of the link, the leverage (moment) changes, and a few things happen. The wheel rate lessens (softer rear suspension), the bike is lowered, and the travel increases. For me, it's exactly what I want.
I made up a few sets to experiment with, and when i get a chance to try them, I'll post the results.
Here are the numbers.
KDX 1 118
KDX 2 ??
KDX 3 124
KLX 4 130 (2" drop)
Stock KLX250 117
My home made links 120, 124
Notice that the stock KLX 250 link is 117 (I looked at mine, it's stamped on the side as well), so if you could get a set of these on the KDX, you'd see about a 1" drop without any adjustment, and a little softer suspension. Note that you can also adjust the drop (sag) out, and just use it to soften up the rear a bit. It could be a budget tuning solution for your rear suspension.
I mistakenly thought the KDX 1 was 116 (bad memory), and knew the KDX 3 was 124, so I made the assumption that the KDX 2 was 120. Looking at the number, it;s probably 121 (but I can't be be sure of this), so the 120 may turn out to be perfect, or totally not perfect. We'll see.
If you want to make your own set, you will need 2 pcs. of 1/4 x 1 1/4" (or 1 1/2") flat bar, and a 15 mm drill bit. Mine are 1 1/2" milled down to 1.3", but 1 1/4" would work fine. The stock links are 6 mm thickness, so the 1/4" is only .010" thicker, and will work just fine.
Edit: When I installed the links on the KLX, I found out that they're 8 mm thick, and not 6 like the KDX. You could use 5/16" flat bar, or 1/4" and a waher like I did.