PIVOT WORKS Fork Rebuild Kit (Seals and Bushings) for KAWASAKI KDX 200, KDX 220 and YAMAHA TTR 250 1995-2006

On KAWASAKI KDX 200, KDX 220 and YAMAHA TTR 250 from 1995 to 2006, the PIVOT WORKS PWFFKK01020 fork rebuild kit fits in place of the original part. Over the hours, fork bushings lose their coating and the seals harden: the fork leaks, develops play and sticks on small bumps. This kit includes the oil seals, dust wipers, bushings and O-rings needed for a complete rebuild.

Specifications

• Brand: PIVOT WORKS
• Manufacturer part number: PWFFKK01020

When to replace it?

• Oil on the fork tube or on the front brake disc.
• Play when pulling and pushing the front wheel with the fork extended.
• Fork that sticks or creaks, scored bushings or copper showing on teardown.

At the first leak or the first sign of play. As a Cross-Mania guideline: fork oil change every 20 to 30 hours of racing, full rebuild (seals and bushings) every 40 to 60 hours, once a season for recreational riding.

Fitting tips

1. Drain the fork and remove the cartridge following the bike's manual.
2. Remove the dust wiper and clip, then separate the tube from the outer leg with short sharp pulls: the outer bushing and the old seal come out with the tube.
3. Cover the tube end with plastic film, slide on the new dust wiper, oil seal and outer bushing without cutting the lips, then fit the new inner bushing last.
4. Fit the outer bushing and the oil seal squarely with a driver that matches the tube diameter.
5. Refill with fresh fork oil at the manufacturer's level and viscosity.

Why PIVOT WORKS?

Pivot Works specialises in chassis rebuild kits for off-road bikes and quads: bearings, seals, bushings and spacers grouped by model. The brand claims original-equipment quality, durability and fit, and since 2012 has offered a lifetime replacement of its kits in case of failure (once per kit).

Spare parts and items to plan

• Fork oil : LIQUI MOLY 10W 500 ml

Frequently asked questions

What is in the kit?
The oil seals, dust wipers, upper and lower bushings and O-rings for the model. Compare with the photo and your original parts if in doubt.

Should the bushings be replaced if only the seals leak?
It is recommended: a worn bushing lets the tube move and quickly damages new seals. The kit lets you replace everything in a single teardown.

Compatibility

Check the exact model and year of your bike in the list below before ordering.

Fits:
KAWASAKI KDX 200 2006
KAWASAKI KDX 200 2005
KAWASAKI KDX 200 2004
KAWASAKI KDX 200 2003
KAWASAKI KDX 200 2002
KAWASAKI KDX 200 2001
KAWASAKI KDX 200 2000
KAWASAKI KDX 200 1999
KAWASAKI KDX 200 1998
KAWASAKI KDX 200 1997
KAWASAKI KDX 200 1996
KAWASAKI KDX 200 1995
KAWASAKI KDX 220 2005
KAWASAKI KDX 220 2004
KAWASAKI KDX 220 2003
KAWASAKI KDX 220 2002
KAWASAKI KDX 220 2001
KAWASAKI KDX 220 2000
KAWASAKI KDX 220 1999
KAWASAKI KDX 220 1998
KAWASAKI KDX 220 1997
YAMAHA TTR 250 2006
YAMAHA TTR 250 2005
YAMAHA TTR 250 2004
YAMAHA TTR 250 2003
YAMAHA TTR 250 2002
YAMAHA TTR 250 2001
YAMAHA TTR 250 2000
YAMAHA TTR 250 1999