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LEVEL 2 Fork Kit (250mm travel) - suitable for both CRF250L & Rally models.


Note. This fork kit is a direct replacement for both the CRF250L & Rally models, however CRF250L owners looking to upgrade both their front and rear suspension, please see specific note in the IMPORTANT INFORMATION section.


Our 250mm travel Open Cartridge Fork Kit has been developed in conjunction with our engineering partners TracTive Suspension in the Netherlands, and offers a range of spring rates and correspondingly improved and adjustable damping characteristics to suit a wide range of all-terrain and off-road riding conditions.


Designed to utilise the full range of travel available, while our LEVEL 2 (250mm) travel fork kit offers the same overall travel as the OEM specification, now that you have the forks sprung with correct rate for your weight (ie. without the excessive sag of the soft OEM components) you will have effectively raised your ride/seat height by around 30-40mm (depending on your personal sag preference) - in other words, you now have more of the total travel available than before, and a corresponding increase in seat height and ground clearance.


In that regard, we also suggest purchasing/fitting our own longer side stand (link below) when upgrading to the LEVEL 2 suspension, as the taller overall height of the bike will cause it to lean over excessively when on the OEM side stand.

LEVEL 2 Fork Kit specifications


Our unique big-bore fork cartridge kit features a 35mm diameter body and piston (approximately 300% more surface area than the OEM piston) which offers a dramatic increase in oil flow for far more precise damping control under a wide range of conditions.


A single proportional adjuster (at a fixed ratio of 80% Compression and 20% Rebound) means the damping can be quickly adjusted to your preference using a 4mm allen key (with 18 clicks of adjustment) at the top of the left hand fork. Our big-bore cartridge also features a PDS check-valve circuit for improved damping control and cushioning towards the end the stroke.

Both billet aluminium machined fork caps incorporate external adjusters for spring preload (+/- 10mm), together with low-profile pressure-relief bleed screws, which can always be upgraded with aftermarket quick-release bleeder valves if desired. 


The Rally-Raid Products CRF Fork kit completely replaces the OEM internal components of the original forks - and utilises a pair of linear-wound springs (one in each leg, rather than just a single spring in the right hand side), together with our adjustable big-bore damping cartridge which replaces the original components in the left hand leg.  The right hand leg now also features a matching preload adjuster, and a pair of billet aluminium fork caps complete the installation.

Our CRF fork springs are available in three suggested rates, depending on your rider & luggage weight (weigh yourself with all your riding gear on):


SOFT: 3.6N/mm - up to 75Kg (‘comfort’ spring for lighter riders and/or modest speed trail riding conditions)


MEDIUM: 3.9N/mm - up to 95Kg (supplied as standard)


HARD: 4.2N/mm - over 95Kg (for heavily laden machines and/or more aggressive off-road riding)




Note. This fork kit is a direct replacement for both the CRF250L & Rally, although the earlier 250L models do require an extra fork preload bush (supplied in our kit).


A 43mm Fork Seal Driver tool will be required to replace the fork seals when fitting our kit - so if you do not have one already, then please consider purchasing our own design (link below), which is specifically shaped to work with both the OEM and our recommended upgraded SKF double-lipped seals.


While you have the forks apart, we also suggest changing the hard-plastic OEM fork seals with much softer and higher quality SKF Dual Compound fork seals, which give a much smoother action and longer life (available to order separately, see link below).


Fitting our CRF fork kit is designed to be straightforward, but does require some basic knowledge of fork disassembly and suspension work. If you do not feel able/or have the facilities to do this at home, we recommend you contact a suspension specialist to perform the work for you.


SPECIAL NOTE for CRF250L model owners: the LEVEL 2 fork kit is a direct replacement for the OEM travel 250L forks, however the 250L model has a shorter travel rear shock than the 250 RALLY, so you must specify the LEVEL 1 shock to retain the original ride height front and rear for the 250L model.


CRF250 Fork Kit Fitting Instructions (downloadable PDF)