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Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs [1] a few turns in order to relieve excess pressure from the inside of the
fork. To do this, place the motorcycle on a stand with the front wheel lifted
off the ground. When riding the motorcycle mainly on the road, it will suffice
to have this job performed in the course of the periodical maintenance
service.
Excessive pressure in the interior of the fork can cause leaks in the fork. If
your fork is leaking, it is recommended to open the breather plugs before hav-
ing the seals replaced.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows [2] are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind the
dust-protection bellows. If this dirt is not removed, the oil sealing rings located
behind it may start to leak.
Use a screwdriver to lift the dust-protection bellows out of the outer tubes
and slide them downward.
Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine
oil. Then, push the dust-protection bellows into the outer tubes by hand.
No oil may reach the front tire or the brake disks since this would consider-
ably reduce the tire's road grip and the braking effect of the front brake.
MAINTENANCE WORK ON CHASSIS AND ENGINE
»
Replacing fork springs
If you weigh less than 75 kg or more than 85 kg, you should install the respec-
tive fork springs. The correct spring rate is shown in the illustrations. The stan-
dard spring is shown in bold print. The type number of the telescopic fork is
embossed on the inside of the fork leg axle passage.
If you are uncertain which spring to use, contact your KTM workshop.
According to our experience, the damping rate of the compression stage can
remain unchanged. The damping rate of the rebound stage can be reduced
by a few clicks for a softer spring or increased by a few clicks for a harder
spring.
1
MODELL SOFTER STANDARD HARDER
14187C02 125/200 XC-W, EXC 3,8 N/mm
4,0 N/mm
4,2 N/mm
14187C27 125 EXC Six Days, 200 XC 4,0 N/mm
4,2 N/mm
4,4 N/mm
14187C04 250/300 XC-W, EXC 4,0 N/mm
4,2 N/mm
4,4 N/mm
14187C28 250/300 XC, EXC Six Days 4,2 N/mm
4,4 N/mm
4,6 N/mm
2
65
SPRING RATE
70 75 80 85 90 95
Riders weight inclusive gears in kilogram
4,2 N/mm
4,4 N/mm
4,0 N/mm
for example front fork 250 EXC