KX Fork Guards & "CR Style" Brake Routing--How To
 

This covers two mods:

Stage 1--KX Fork Guards
Stage 2--Braided Steel Front Brake Line With CR Routing


Stage 1--I put the KX guards on simply to get to stage 2, but there are other advantages such as--cheaper, much easier to find, they flex more instead of crack, & IMHO they look alot better. Plus some of you going for the black plastic thing--you can easily get these in black.

I have heard of people putting KX guards on the KLX--its old hat--butI never saw a write up or how much modification was involved so here you go.

You need KX guards & guides. The guards are the same 94-03 (or so). The guides are from the 94-95. In 96 Kawasaki went to a larger fork so I do not know if those guides work or not--they may require a "spacer" inbetween the guide & fork. The easiest thing isjust order UFO 94-95 guards--they come with the guides you need.

Brake side: The two front holes line right up, the side one is too far back but the guard is right up close to the mount...

http://img.photobucket.com/albums/v2...PIC00002-1.jpg

http://img.photobucket.com/albums/v2...1/PIC00003.jpg

All you need to do is take some time, mark the new hole location & drill it. Then cut off the excess guard. A Dremel does wonders.

http://img.photobucket.com/albums/v2...1/PIC00004.jpg

Install the new KX guide--its the one with the brake line loop. It will snap into place when you've got it.

http://img.photobucket.com/albums/v2...1/PIC00005.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

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RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

The other side is off more. Only one bolt can go in front & the side needs a spacer as well as a new hole.

http://img.photobucket.com/albums/v2...PIC00007-1.jpg

But one of the stock KLX spacers fitts perfect.

http://img.photobucket.com/albums/v2...1/PIC00010.jpg

Then I put in a loop for the odo cable. (I explored other options including using the brake side guide for the odo cable but nothing worked as good as this, other setups put too much kink in the cable or bent it in towards the wheel).

http://img.photobucket.com/albums/v2...1/PIC00011.jpg

At this point you can stop or choose to move to stage 2.

http://img.photobucket.com/albums/v2...1/PIC00012.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Wrong image tag, use [IMG] and [/IMG].

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Nobrakes staightened me out.

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Those look really good!

Can't wait to see stage 2.

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

AGHHH--I just lost a huge portion of text...that is whay I am trying to break it up.

Ill try again.

STAGE 2

The whole point of this for me is to run a stainless line routed via the correct "CR Style" aka down the inside of the fork leg. The stock way, needless to say, is poor I'm sure everyone can see. the reason it is like that is because Honda had a patent on the "correct" way when the KLX was designed. It expired & now everyone does it this way.

Long story short we need a long line. The MXers run the lines across the number plate--I dont think that will fly with our gauges & headlight. So I figured there are only 2 real options---we need a line from a bike with an inverted fork & a headlight---that leaves WRs & CRFXs. I went WR (the early models, not late models). I searched all the manufacturers & the only one that gave me warm fuzzies enough to order the parts that this would work was the Ride Engineering line. You also need the universal brake line clamp that bolts to the fork guard.

I ordered from MX South--cheaper than striaight through Ride even though my package was shipped straight from ride.

Now your probably asking--why do we need the KX guards? The KLX guides IMO have no place to mount the clamp & I doubt the guides would work as they have channels running along the back. Not to mention the holes they would have in the front...

http://img.photobucket.com/albums/v231/xrz71/0001-1.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

I was worried the Ride line would have aluminum fittings but to my pleasant surprise they are steel & MADE BY GALFER! YEA! If you have aluminum fittings on a stell line they can corrode & fail.

Now install the line & bleed it. The fittings have a right & wrong--the top fitting should poit upward.

http://img.photobucket.com/albums/v2...PIC00002-2.jpg
http://img.photobucket.com/albums/v2...PIC00003-1.jpg

Again, take time & route the line down the inside of the fork leg. Reposition the stiffing section of the line as necessary. Mark the holes for the clamp & install.

http://img.photobucket.com/albums/v2...PIC00004-1.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

http://img.photobucket.com/albums/v2...PIC00006-1.jpg



The hoops on the front of the KX guides have to go. Ride recommends removing them completely but I dont see why this wont work. I cut the hoops of & sanded them smooth. you want at least the rings of the guides so when roost or wind push against the guards they rub the guides, not the fork leg. I cut the odo side just so it matched.

There is plenty of room between the clamp bolts & the guide.

http://img.photobucket.com/albums/v2...PIC00011-1.jpg

Works good so far!
http://img.photobucket.com/albums/v2...PIC00010-1.jpg
http://img.photobucket.com/albums/v2...PIC00007-2.jpg
http://img.photobucket.com/albums/v2...PIC00009-1.jpg
http://img.photobucket.com/albums/v2...PIC00005-1.jpg
http://img.photobucket.com/albums/v231/xrz71/0001-2.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Nice job, KLXer! Great photos, too.

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Great write up. Idid the same thing with my KLX300 after destroying the stock brake line and a Galfer made for the KLX. The Galfer lasted for two rides. I also have a Four Stroke Works brake line guard. I have tried just about every combination of left side guide on the right side, loops, clips, etc., for the odometer cable. I pretty much ride only off road and everything I tried either put the cable in a bind, the fork guide/guard in a bind or stuck out too much and got snagged off road. My solution was the simplest of all. A black zip tie (not too tight)around the fork and cable. It works perfect and blends in well. I also used the Ride Engineering stuff and in harsh off road riding I have not needed the guide on the fork on the left side. The three bolts hold the guard very tight. The right side is a different story. I think you need the guide.Only havingtwo bolts allows the guard to move some when rubbed against. The guard will keep it fairly straight. I have to re-position the guard in the guide after most but not all rides. Also I'm not sure how the 250 "dash" is set up but on the 300 I found the routing of the brake cable worked better by going through the lower triple clamp guide first and eliminating the upper triple clamp guide. It makes it a little closer to the KX routing it was designed for. You will like this much better, especially if you ride off road, as the brake lineis not nearly assusceptible to damage.

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Looks great, like it should have in the first place!

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

Actually, I rooted around thumpertalk for awhile & saw your pics & threads on the subject so really you deserve alot of the credit--:) I just went in a little different directionon which bike to source the brake line from. You used the KX line which is shorter, I used a WR wich is longer & that enabled me to use the upper tripple line guide. It is routed like it was designed for on the WR. The gauges hog all the space between the headlight shell & the tripple on the 250S.

This is the line I used. I routed it just like that.

http://www.ride-engineering.com/imag...L-02012-CL.jpg

RE: KX Fork Guards & "CR Style" Brake Routing--How To
 

You did a good job figuring out that WR line.I really like the way the KX line worked out on the 300. It's clean and tucks away nice. I will be doing a riding buddies bike soon also. He broke a stock fork guard on our ride last weekend from a crash. Unless they have changed the material of the stock fork guards, which I don't think they have, they get very brittle with age andif you look at them wrong they will brake. My buddies shattered into pieces like mine did. The KX guards would never have broke the way ours did. He has had the parts for quite a while, after seeing mine,and nowhe doesn't have an excuse not to get them on. Again, if you ride technical off road, the CR type line IMO is a must. It's no fun trying to get back to camp without a front brake.