WORKSHOP MANUAL FRONT FORK KTM SXS 2005
03 - 2005WORKSHOP MANUALFRONT FORKKTM SXS2005
ContainsIntroductionExploded viewPart list KTM front fork SXSSetting list KTM 125 SXSSetting list KTM 250 SXSSetting list KTM 450/540 SXSDisassembling the front fork out of the motorcycleAdjustmentsDisassembling the cartridge out of the front fork legInspection of the springDisassembling the inner-tube / outer-tubeInspection of the outer-tubeInspection of the DU-bushes, support ring and sealsInspection of the inner-tubeDisassembling the closed cartridgeRelease the nitrogen pressureInspection of the piston rodDisassembling the membrane holderInspection of the check valve springDisassembling the screw sleeveDisassembling the rebound adjustment adaptorDisassembling the tap reboundInspection of the rebound settingDisassembling the screw-cap / membrane CCAssembling the screw-cap / membrane CCDisassembling the tap compressionInspection of the compression settingAssembling the holder membraneAssembling the tap reboundAssembling the rebound adjustment adaptorAssembling the screw sleeveAssembling the closed cartridgeBleeding the closed cartridgeOn pressure with nitrogenAssembling the inner-tube / outer-tubeExplanation of the spring preloadAssembling the cartridge in the front fork legFilling oil in the front fork legPosition of the compression and rebound adjustmentMounting the front fork in the motorcycleAir release screwTechnical InformationRecommended periodic service intervalSpecial 1382
IntroductionGeneral noticePay attention to the following notes, when you are working with WP Suspensionproducts as described in this workshop manual.Always use clean and professional tools.Regalur you need next to the general equipment, the special tools of WPSuspension.These tools with a unique “T” number (available byWP Suspension & KTM) protect you from damaging the parts.Always use aluminium protector-plates, when clamping our products or parts inthe vice.Always replace damaged parts.Clean all parts before assembling.Caution:Many times it is necesarry to assemble parts with T131 and T132.These parts must to dry for at least four hours!!!T Always use the special WP Suspension tools! Use safety glasses! Place a fire extinguisher near by in case of emergency! Use protecting glooves! Contains high pressure! Caution! - It needs your extra attention - for example theassembling direction!3
Exploded view4
Part list KTM front fork SXSPos.Part descriptionArticle 06162Ball-steel d3Inner-tube SXS’05 d48 L595 TiLock washer SB58Lock nut M6x1Cil.head screwSupport ring d50xd57.6x1.5Oil seal washer d4Outer-tube 54/60 L577Screw capTube d35xD 37.5Screw sleeve M24.5x1DU-bush d47xd49x20 DDL02DU-bush d48xd52x12 DDL02DU-bush d14xd12x10 DDL02Rubber plugO-ring N.B.R. 24x2O-ring N.B.R. 38x2O-ring N.B.R. 261.5O-ring N.B.R. 48x2O-ring N.B.R. 17x2O-ring N.B.R. 21x2O-ring N.B.R. 46x2Rubber capO-ring N.B.R. 2x1.5O-ring N.B.R. 6x1.2O-ring N.B.R. 9.5x1.5O-ring Viton 7x1.5O-ring N.B.R. 4x1.5Bush d10x3Axle-clamp Ma brake KTM SXR “03Axle-clamp MA ri KTM SXR “03Oil seal d12xd22x9.5Bolt with flange M 8x25Holder adj. tube d4 L 18Adj. screw 1.8Retainer Ring d10.8Needle bleed adj.Bolt M20x1 L33Tap compression d2.5 ‘03Check valve StopPiston rod tap reboundMechanism needle C 4N/mmShuttle valve spring C0.4 Lo 8Lock washer d20Rebound spring L33.5 d 13 c 11Lock washer d30Membrane CCPiston rod d12 M9x1 L405Oil seal d48xd57.8x9.5 ‘03Dust stripper d48 d58.4 2222The amount of piecesare for both fork legs5
Part list KTM front fork SXSPos.Part descriptionArticle 192939495120180Spring d2.9 L6.5Chek valve spring th 0.7Adj. Tube L 371Adj. tube L 85Hydr.stop d28Guiding ring D44.2xs39.3Ring D42.4x6.5Ring D23.45x2.65Support ring D37.5Plug G1/8clamping disccheck valve holder L 7Piston ring 5x1x68Spacer 43x35x2.5Spacer 43x35x5Spacer 43x35x1.5Contra nut M12x1 SLW17Washer 32x42x2.5Tube d23 L417 CCPiston rod d12 L117Adaptor guiding bushWasher copper 20.5x26x1Membrane holder cpl.Adj.screw M5Spring d 3.9 C 1.1N/mm Lo 8mmPin valveO-ring Viton 1.5 x 1Piston rebound bleed 1.2Piston .42222222222222222222222222222The amount of piecesare for both fork legs6
Setting list KTM 125 SXSSetting4860 MXMA front fork 14.18.7A.14KTM 125 SXS 2005The amount of piecesis for one fork legCompressionPos160161162163164165166167168Part descriptionShim 6x16x0.25Backpl. 6x8.5x0.20Shim 6x12x0.1Shim 6x14x0.1Shim 6x16x0.1Shim 6x18x0.1Shim 6x20x0.1Shim 6x22x0.1Shim 6x24x0.1Article 11114Compression check-valve setting181Check valve d8xd24x0.44860.0061.1Shim 6x14x0.25Backpl. 6x11x0.30Shim 6x12x0.10Shim 6x13x0.10Shim 6x14x0.10Shim 6x16x0.10Shim 6x12x0.10Shim ound check-valve setting130Shim 8x10x0.20131Shim 8x14x0.10132Shim 8x16x0.10133Shim 8x18x0.10134Check valve .4860.0215.21123Spring1Spring 4,2 N/mm9141.0025.1AdjustmentsPosition compressionPosition reboundOil volume (ml)CodeStroke check-valve comp. (mm)Stroke check-valve reb. (mm)Total length (mm)Stroke (mm)Gas pressure (BAR)Preload spring (mm)Spring length with spacers 1001011021031041051061077
Setting list KTM 250 SXSSetting4860 MXMA Front fork 14.18.7A.15KTM 250 SXS 2005The amount of piecesis for one fork legCompressionPosPart descriptionArticle 4Shim 6x16x0.25Backpl. 6x9.5x0.20Shim 6x12x0.10Shim 6x13x0.10Shim 6x14x0.10Shim 6x15x0.10Shim 6x16x0.10Shim 6x17x0.10Shim 6x18x0.10Shim 6x19x0.10Shim 6x20x0.10Shim 6x21x0.10Shim 6x22x0.10Shim 6x23x0.10Shim 860.0063.1111111111111154860.0061.1Shim 6x14x0.25Backpl. 6x11x0.30Shim 6x12x0.10Shim 6x13x0.10Shim 6x14x0.10Shim 6x16x0.10Shim 6x12x0.10Shim ound check-valve setting130Shim 8x10x0.20131Shim 8x14x0.10132Shim 8x16x0.10133Shim 8x18x0.10134Check valve .4860.0215.211239141.0026.1Compression check-valve setting181Check valve pring 4.4 N/mmAdjustmentsPosition compressionPosition reboundOil volume (ml)CodeStroke check-valve comp. (mm)Stroke check-valve reb. (mm)Total length (mm)Stroke (mm)Gas pressure (BAR)Preload spring (mm)Spring length with spacers (mm)242539514.18.7A.151,50,49403001,05,55098
Setting list KTM 450/540 SXSSetting4860 MXMA Front fork 14.18.7A.16KTM 450/540 SXS 2005The amount of piecesis for one fork legCompressionPosPart descriptionArticle 4Shim 6x16x0.25Backpl. 6x9.5x0.20Shim 6x12x0.10Shim 6x13x0.10Shim 6x14x0.10Shim 6x15x0.10Shim 6x16x0.10Shim 6x17x0.10Shim 6x18x0.10Shim 6x19x0.10Shim 6x20x0.10Shim 6x21x0.10Shim 6x22x0.10Shim 6x23x0.10Shim 860.0063.1111111111111164860.0061.1Shim 6x14x0.25Backpl. 6x11x0.30Shim 6x12x0.10Shim 6x13x0.10Shim 6x14x0.10Shim 6x16x0.10Shim 6x12x0.10Shim ound check-valve setting130Shim 8x10x0.20131Shim 8x14x0.10132Shim 8x16x0.10133Shim 8x18x0.10134Check valve .4860.0215.211239141.0032.1Compression check-valve setting181Check valve pring 4.6 N/mmAdjustmentsPosition compressionPosition reboundOil volume (ml)CodeStroke check-valve comp. (mm)Stroke check-valve reb. (mm)Total length (mm)Stroke (mm)Gas pressure (BAR)Preload spring (mm)Spring length with spacers (mm)242539514.18.7A.161,50,49403001,05,55099
Disassemble the front fork out of the motorcyclePlace your motorcycle on a stand.Notice the position of the front fork in thetriple-clamps.1. To remove the front fork. Read yourKTM Instruction Manual or WorkshopManual.2.10
AdjustmentsTake notice of the position of thecompression adjustment!Count the clicks by turning the adjustmentscrew clockwise till fully closed.For the standard position see setting list.Remove the rubber cap out of the axleclamp.Take notice of the position of the reboundadjustment!Count the clicks by turning the adjustmentscrew clockwise till fully closed.For the standard position see setting list.11
Disassembling the cartridge out of the front fork legPlace clamping block T1403S in the vice.TClamp the outer-tube of the front fork leg inthe clamping block at the level of the lowertriple-clamp.TPlace T14.017 on the screw-cap of thefront fork leg.TUntighten the screw-cap.T12
1. Remove the front fork leg out of the viceand move the outer-tube downwards to theaxle-clamp.2.Drain the oil out of the front fork leg.For only replacing the spring or changing thespring preload13
Place the front fork leg in the vice accordingto the position in the picture.3.1. screw the rebound adjustment holder outof the axle-clamp.(Size 19)14
2.3.Push the cartridge downwards and place.(Do this with a second person).slide T14.020 over the piston-rod justbelow the contra nut. (art. no. 4860.0459)T15
Screw the rebound adjustment holder fromthe nut.(Size 19 and 17)TUnscrew the rebound adjustment holderfrom the piston-rod.Pay attention to the rebound adjustmenttube, remove it when it comes out of thepiston-rod!TPush the cartridge downwards and.T.remove T14.020.T16
Release the spring pressure on thecartridge slowly.Remove the closed cartridge complete.“The closed cartridge complete”Remove the spring with the spacer.T17
Inspection of the springOnly for replacing the spring orchanging the spring preload!It is necessarry to place the front fork legaccording to the picture for about 5 minutes.The amount of rest oil that stay left in thefront fork leg is 10ml.See the setting list for the correct amount ofoil volume, this oil volume is minus the 10mlof rest oil.For example 385ml - 10ml 375ml.The total length of the spring (withoutspacers) is 505mm /- 3mm.Replace the spring when the total length isless then 495mm.Inspect the coils of the spring if they are notflat, incase they are, you have to replace thespring.18
Disassembling the inner-tube / outer-tubePlace the front fork leg in the vice accordingto the picture.Remove the dust stripper very carefully .Do not damage the inner- or outer-tube!Slide the dust stripper downwards.Remove the lock washer with ascrewdriver.The lock washer is on one side chamferedto disassemble it easier!19
Heat the surface of the outer-tube nearthe oil seal to a temperature of 50 C.T1. Remove the front fork leg out of the viceand pull with both hands the outer-tube fromthe inner-tube.2.20
Inspection of the outer-tubeThe outer-tube.TInspect the outside surface of theouter-tube if there isn’t any damagebecause of (for example) stones.Inspect the inside running surface of theouter-tube on scratches.Also inspect the anodized coating of therunning surface.Micrometer for measuring the oil seal andDU-bush chambers of the outer-tube.21
Measure the chamber for the DU-bush.TThe maximum diameter is: 52.15mmMeasure the chamber for the oil seal.The maximum diameter is: 57.50mmMicrometer for measuring the diameter ofthe running surface of the outer-tube.Place at the side of the screw cap themicrometer 300mm into the outer-tube.Measure the diameter of the running surfaceand measure again after rotating the outertube 180 .The maximum diameter is: 49.20mm22
Place the inner-tube according to the picturein the vice.Remove the DU-bush from the inner-tube.Remove the outer-tube DU-bush.Remove the support ring.23
Remove the oil seal.Remove the lock washer.Remove the dust stripper.- Dust stripper- Lock washer- Oil seal- Support ring- DU-bush outer-tube- DU-bush inner-tube24
Inspection of the DU-bushes, support ring and sealsReplace the DU-bush if the surface isfeeling rough.The best way to do this is to compare itwith a new one!Replace the DU-bush when you seethrough the surface a bronze color.Replace the DU-bush if the surface isfeeling rough.The best way to do this is to compare itwith a new one!Replace the DU-bush when you seethrough the surface a bronze color.25
Check if the support ring is not bended.Always replace the dust stripper andoil seal with every service!See periodic service interval!26
Unscrew both bolts out of the axle-clamp.T1. Heat the axle-clamp.T2.TPlace T1404S in the inner-tube with.T27
2.TPlace T1404S in the inner-tube with.T.the pin (T605) through the holes in theinner-tube.TUntigthen the inner-tube.T28
Unscrew the inner-tube from theaxle-clamp.Take the axle-clamp out of the vice.Axle-clamp complete!29
Inspection of the inner-tubeInner-tube.Inspect the outside running surface of theinner-tube on scratches, wear and tear.When the scratches are sharp and theyare not to deep, try to polish them with aScotch Brite hand pad.Micrometer for measuring the outsidediameter of the inner-tube.30
1. Measure the outside diameter of theinner-tube, rotate the inner-tube 180 andmeasure again. Repeat these measurmentson several places of the inner-tube.The maximum diameter is: 48.005mmThe minimum diameter is: 47.950mm2.3.Clock gauge for measuring the straightnessof the inner-tube.31
Measure the straightness of the inner-tube,rotate the inner-tube 360 .The maximum travel is: 0.06mm32
Take the spacer out of the axle-clamp.Use air pressure to remove.the O-ring out of the nut of the axle-clamp.Remove the hydraulic sleeve.33
Axle-clamp with the components.34
Disassembling the closed cartridgeThe closed cartridge complete.1. Remove the rebound adjusting tube.2.Clamp the reservoir of the cartridge in thevice according to position in the picture.35
Release the nitrogen pressureUnscrew the Allen bolt that is nearist to thecompression adjustment screw.(Size 3)Remove the Allen bolt with seal out of thescrew-cap.Allen bolt with seal.Special tool T14.019.TProtecting cap.36
Remove the protecting cap of the needleand stick the needle through the middleof the filling rubber plug.You will hear that the nitrogen pressureis releasing the membrane.TPlace T14.018 on the screw-cap.TUntighten the screw-cap of themembrane holder.TLift the screw-cap of the membrane holderout of the reservoir with a screw driver.37
1. Take the membrane holder out of thereservoir.2.Drain the oil out of the cartridge.Clamp the closed cartridge in the viceaccording to the picture!38
Heat the screw sleeve.TUntighten the screw sleeve.(Size 24)TUnsrew the screw sleeve out of thetube.TPull the piston rod out of the tube.T39
The complete piston rod with the reboundsetting.Pay attention to the piston ring!T40
Remove the tube d35xD37.5.Tube d35xD37.5 with guiding ring.1. Remove the guiding ring241
Place clamping block T14.016 in the vice.TPlace the piston rod in the vice according tothe picture.1. Remove the piston ring.T2.TUntighten the tap rebound.(Size 17)T42
Screw the tap rebound with needleand spring out of the piston rod.TRemove the rebound spring.TRemove the steel washer.TRemove the screw sleeve.T43
Inspection of the piston rodPiston rod.Replace the piston rod if you have inspectthat the surface of the piston rod hasscratches and or indentations.Always replace also the DU-bush d12 of thescrew sleeve.Use a clock gauge for measuring thestraightness of the piston rod.Measure the straightness of the piston rod,rotate the piston rod 360 .The maximum travel is: 0.12mm44
Micrometer.Measuring the outside diamater of thepiston rod.Measure the diameter of the piston rod,rotate the piston rod 180 and measure thediameter again.Repeat these measurments on several places ofthe piston rod.The maximum diameter is: 12.00mm.The minumum diameter is: 11.92mm.45
Place clamping block T14.015 in the vice.TScrew the screw sleeve handtight back intothe tube.completely.Clamp the tube at the level of the screwsleeve in the clamping block.T46
Disassembling the membrane holderThe membrane holder complete.TScrew the plug out of the membraneholder. (Size 4)This plug is for factory production use!TRemove the plug.TRemove the O-ring.T47
Remove the O-ring.TDisassemble the springring.Pay attention in wich groove thespringring is assembled!By changing the position of the springring inthe groove you will change the springpreload!The distance between the grooves is2.5mm. This means 2.5mm more or lessspring preaload!TPlace the membrane holder in the viceaccording to the picture.The adjustment screw of the pressurerelease valve.48
Unscrew the adjustment screw with acorrect fitting screwdriver.1. Screw the adjustment screw out of themembrane holder.T2.Turn the membrane holder up side downand remove the spring.49
The check valve pin.It is not possible to disassemble thecheck-valve pin out of the membrane holder!50
Inspection of the check valve springCheck valve spring.The length of the spring must be8.0 0.2mm.Replace the check valve spring if the lengthis less then 7.8mm.51
Place the tube in the clamping blockT14.015 at the level of the screw sleeve.Heat the membrane holder at the levelof the springring groove.TUntighten the membrane holder withT14.017.TScrew the membrane holder off the tube.T1. Remove the O-ring inside.52
2.The membrane holder with thecomponenets.53
Disassembling the screw sleeveTurn the screw sleeve out of the tube.Screw sleeve complete.Remove the O-ring.Remove the springring.54
Remove the check-valve ring.1. Screw the threaded bush T14.023 onthe screw sleeve.T.till about 0.5mm just above the edge ofthe thread of the screw sleeveTPlace the screw sleeve with clampingblock T14.015 in the vice.T55
Heat the threaded bush to a temperatureof 50 C.T1. Lift the oil seal with a screw driver outof the screw sleeve.T2. Pay attention to the assemblingdirection.TThis side of the oil seal is visible when theoil seal is assembled in the screw sleeve.Always replace the oil seal!56
Remove the threaded bush.TUse T14.022.T.to press,T.the DU-bush out of the screw sleeve.Always replace the DU-bush d12!T57
The screw sleeve with components.Inspect the surface of the check vakvering on scratches, wear and tear.58
Disassembling the rebound adjustment adaptorThe rebound adjustment adaptor complete.Remove the O-ring.Remove the copper washer.Always replace the copper washer.Turn the adjustment screw clockwise.59
.and remove the needle.Remove the O-ring insid
WORKSHOP MANUAL FRONT FORK KTM SXS 2005 03 - 2005. Contains Page Introduction 3 Exploded view 4 Part list KTM front fork SXS 5 Setting list KTM 125 SXS 7 Setting list KTM 250 SXS 8 Setting list KTM 450/540 SXS 9 Disassembling the front fork out of the motorcycle 10 Adjustments 11 . WP Suspension & KTM) protect you from damaging the parts.
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BOBINA INTEGRATA KTM 990 SUPERDUKE R Prezzo consigliato 88,00 IVA esc. APPLICAZIONI Marca Modello Cil. Anni. KTM LC4 Duke 690 2012-2012 KTM LC4 Duke R 690 2012-2012 KTM LC8 Super Enduro R 950 2006-2009 KTM Adventure 990 2006-2013 KTM Adventure R 990 2009-2013 KTM Adventure S 990 2006-2012 KTM Super Duke / R 990 2005-2013 ALTRE. Art. 165517
KTM 150 SX 2015–2020 KTM 250 SX 2015–2020 KTM 250 SX-F 2015–2020 KTM 250 SX-F FE 2015–2017 KTM 350 SX-F 2015–2020 KTM 450 SX-F 2015–2020 KTM 450 SX-F FE 2014–2020 If your motorcycle is listed above, proceed with the installation using these instructions. . Refer to your OEM Service Manual for instructions on this process.
ktm ktm 450/505 sx 2008-10 aluminum full system 50-8002 399.95 ktm ktm 450/525 xc 2008-10 aluminum full system 50-8001 449.95 ktm ktm 450/525 xc/505 sx 2008-10 aluminum slip-on 60-8001 209.95 polaris 450 mxr/525s 2008-10 aluminum full system 50-3003 449.95 polaris 450 mxr/525s 2008-10 aluminum slip-on 60-3003 209.95
the fork. Always use the fork clamp to hold the fork; never place the fork in a vice as this causes damage to the tubes. It is possible to counter hold the fork by hand when a compressed air wrench is used. 2 Place the bike stable with the front wheel off the ground. Remove the front fork from the bike. View the bike manual for details.
Dear KTM dealers, We are pleased to present the Spare Parts Catalogue for Duke 250 & Duke 390 Model. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% availability. The KTM spares are subjected to the stringent qualit
Dear KTM dealers, We have pleasure in presenting the 1st 3D Colored Spare Parts Catalogue for KTM 390 DUKE Model. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% availability. The KTM spares are subjected to the stringent quality control standards to ensure longer life of
E hub length D 1 with brake disc D.B.S.E D 2 w/o brake disc B 1 overall length with brake disc B 2 overall length w/o brake disc F H AGMA gear coupling size
