Couple Particulars Re 200x/250sx front end swap

[dreux13]

So I've read all of the conversion threads and mapped out my swap, but have some questions regarding my particular setup trying to decide if some of the suggestions from other threads apply to me or have been found to be unnecessary through the years.

Here's what I've purchased for the setup (all from ebay) w/ prices (shipping included) to help others looking to do project -
- '86 wheel/tire/hub/disk - $46
- '86 Forks/triple - $80
- '84 working brake setup caliper/master/guard/guides - $85

The Plan -

To keep costs down and to preserve the 'look', I am going to keep the 250sx triples and fabricate the axle spacers/caliper spacers.

Now for the Questions -

- Some people mentioned adding 1"+ spacers in the forks using either PVC or aluminum - I'm 200lbs, do I need to do this or is a fresh rebuild or oil change assuming seals are good sufficient?

- Air in the forks - Some of the more recent threads suggest that adding air (generally 5-10psi) is pointless and more of an 80's thing. To add or not is the question!

- 200x forks are about .75" longer than 83-85 200x forks w/ 3" more travel from what I read. Should I push them higher in to the triples or do I want that additional length?

I think that's all I have for questions. Hoping everything shows up as described so I don't have to get in to massive brake rebuild projects! All research pointed that the '84 250R caliper/brackets is a direct bolt-on to the 86 200x forks, so I should be good there.

Any other words of wisdom? This is an '85 250sx in case your wondering.

Thanks for the help!

-Dreux

[DohcBikes]

I don't think the front caliper bracket is the same. Pretty sure you will need the 200x bracket but am not 100% sure at the moment.

Doesn't matter how far you put the forks up in to the triples. Barring tire to fender contact, which you do not want under any circumstance, it will not affect the travel. It will however affect rake, trail, and ride height.

The 1" spacers people are suggesting are for preload. If you are going to use the 30 year old springs, it's a good suggestion. I almost always add pre load to the x frontends, I weigh 175.

As with the above 2 factors in the front suspension, adding air is a preference issue. You can tune with oil and preload only and just use the valves for bleeders, or if you like, you can add a few pounds.

Suspension setups are subjective, and you have not indicated the purpose of the bike.

[dreux13]

Thanks! It's used for mostly woods/trail riding and fire roads at high speed. No real jumping, just lots of wheelies!

[dreux13]

FYI for anyone using this as a reference. The '84 250R front caliper and bracket mount right up to the '86 200x forks. No need for a 200x bracket.