You're making this much more difficult than it needs to be.

 

I'd pay good money for a link on a how-to for someone who did this exact leg swap (not internals per PlanetKLX) on a 2006-7 KLX250S.

Until then.. I'm kinda on my own here unless you have a post you can point to with someone who did this exact swap. I can't know every detail about every KLX250S mod after just buying one.

 

Spend the time to read the article. That's not what they did.

 

You're right. I re-read the article more closely and only looked at pics and skimmed before.

Here's a thread from TT in 2011 with some fork swaps: KLX300 suspension upgrade - stock vs KX - KLX/KLR 125/140/250/300 - ThumperTalk Wish the KX500 fork guy replied with more detail as requested in the thread.

I have a set of 93 KX250 forks on the way. I'll post updates once they arrive and I have time to check everything out. Hope it is easy without needing to get new wheel spacers or caliper adapters.

 

Axel adapters are available, $40 plus postage. Calipers should be a bolt on.
Take a look at who wrote the PlanetKLX article

Ride on
Brewster

 

Check with Kouba on the suspension links. They may be able to steer you to a set of links to raise the back end.
Kouba Link

Ride on
Brewster

 

Sent Kouba an email, will follow up here.

 

Hey thanks - appreciate the reply. Where do I send money for the adapters?

 

First, if the OD of the forks are the same you can swap the legs without clamp change.

Second, if the width of the forks at the axle mount are the same the KX axle can be used with maybe a swap of bearings and seals to match the KLX hub if you have to use it. Both are very likely common numbered parts and a place like Fastenal can get both the bearings and seals. It is also possible the same front hub style was used too. I know the 93 KLX650 and KDXs used the same front wheel as the pre-09s. It is entirely possible it could be a bolt on rather easily especially if you get the front wheel, but worst case you have to do some special spacers and different bearings. (I got a full set of bearings and seals from Fastenal for my 95 KLX650, which actually uses the same front wheel as the KLX250 pre-09)

Third, why do you want the bike to sit higher off the ground? I'd think your issue would be with the peg to seat to bars relationship which could be very easily remedied with a custom seat with about 2-3" more padding and some higher bars. I'd think having the lower footing height would be better for woods riding, being able to foot easier when needed. Put on a thicker seat to get more room for your legs, an easy and probably more comfortable remedy. More padding never hurts... usually less does.

Fourth, some playing with the linkage on the rear shortening them a shade would raise the rear to compliment the increased front height. Might increase travel there, I don't know.

 

All those details on the forks are covered in that article, and he's already using shorter links. Shorter links will raise height and reduce travel.