Has anyone done a Front Fork upgrade that works well off road? Id like to upgrade my suspension and I'm able to find good shocks, but can't seem to find anything for upgrading the front forks.

Could use later DT250 fork up until the went leading axle. Well you could use leading ones but would need the triples due to the different offset but then they hit the tank on full lock. So yes last of the straight axle would be good, maybe "78--ish. Just had a look & "79 goes leading axle. & talking leading axle if ya wanted to go that way the early TT250 forks are nice--forks & triples. I had XT250 early forks on my DT1. Were ok but not as nice as TT250 which are also a mm bigger but better movement too. Mine had "or has" a pretty rough tank on it so just whacked some perfect shaped dents in the tank by smacking the forks around--"rough B-stard" lol.

Just have to move the stops,whats the big deal?

Race Tech makes emulators for pretty much all forks... tunable and seem to work good to me.

Indeed,but I wonder just what is expected of an upgrade . Plushness or stability? Quite a vague target. I cant see him clearing triples.

I second Marks reply. Race Tech gold valve with proper springs and oil...

So I looked at Race-Tech and it doesn't look too bad. around $400 if I do the work myself. Anyone had any experience installing the springs and emulators in their bikes? With that and a set of Ikon shocks on the rear, may make the bike more manageable in a cross country race.

I've done it to three of my bikes that I can remember... maybe 4. Had Canon Racecraft make springs for one. Used shortened stock springs on another (less coils = higher spring rate but have to make sure you don't cut too much and get into coil bind)... can't remember others...

Drill press is handy to drill out the damping rod hole as needed but other than that, pretty easy. Their Tech Support by phone is excellent too.

Point is--if ya move the stops to stop the forks hitting the tank then you end up with a bigger turning circle similar which is damn annoying doing 3 point turns in the driveway. Ended up with a plastic xr tank on mine which gave clearance.
Can't find a still pic of mine but here's a video & can see the RM or PE forks on it. Oh, & i forgot, i now have an AT1 tank which looks like original but smaller & gives clearance on full lock. Did have an XR plastic tank. She's a bit like an AXE with a new head & a new handle--i never quite know what state its in lol. Motor's pretty tweaked--ie Hand Grenade & one hand on the clutch.

Here's a side shot i finally found on photobucket showing the forks.