I recently acquired an ATC250SX for parts, when I noticed the fork tubes were bent I did some searching and found very little info related to replacing them besides the usual 200x (or similar) swap, which is easy enough for some, but not so for others. So I started looking to see if there was any sort of replacement for the fork tubes and while I'm sure there is someone that will make them, I wasn't able to find any good information online. other than the diameter of the tube (33mm) so I went with it. Eventually, I found that a few other motorcycles used 32mm forks, including the Honda Rebel 250. I wasn't able to find the length of the tube anywhere online, but I figured what the heck and bought a pair of used Rebel forks.
After a little fighting, I finally got the forks disassembled and besides some mostly minor differences, most of it was basically the same.
https://www.partzilla.com/catalog/ho...bel/front-fork
#6 in above link is not present on the SX forks and to get the rebel tubes to fit it in the SX housing it needs to be removed
Also the dampening rod #13 is slightly longer.
SX fork diagram for reference: https://www.partzilla.com/catalog/ho...x-a/front-fork
I reassembled the SX fork with the rebel tube and dampening rod temporarily just to see how it all went together...
(LEFT is original SX fork, no changes. RIGHT is the fork with the Rebel tube)
As you may be able to see, the fork is now only slightly longer.
Here are the same 2 forks next to a slightly disassembled rebel fork:
left:SX, middle:combo, right:Rebel
I swapped out the Rebel dampening rod with the SX rod (only swapped part now is the tube itself) and the forks are virtually the same hight, maybe 1-2 mm shorter than the original SX fork. (Becuase the Rebel tube is just that much shorter.)
I am no fork expert, so I have no idea how viable this solution is but I figured I would give it a shot...