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REPAIR MANUAL

2013

Art. no. 4CSen

INTRODUCTION

It is important that you read this repair manual carefully and completely before the start of work.

INTRODUCTION

Only use

ORIGINAL KTM SPARE PARTS.

This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified

experts.

The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in

the interest of technical advancement without, at the same time, updating this repair manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that repair work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

TABLE OF CONTENTS

FORK, TRIPLE CLAMP ................................................. 3

1.1

Performing a fork service ................................... 3

1.2

Disassembling the fork legs................................ 3

1.3

Removing the spring.......................................... 5

1.4

Disassembling the cartridge ............................... 6

1.5

Disassembling the piston rod ............................. 7

1.6

Disassembling the hydrostop unit ....................... 8

1.7

Disassembling the seal ring retainer.................... 8

1.8

Checking the fork legs ....................................... 9

1.9

Assembling the seal ring retainer ...................... 10

1.10 Assembling the hydrostop unit ......................... 10

1.11 Assembling the piston rod................................ 11

1.12 Assembling the cartridge ................................. 12

1.13 Installing the spring ........................................ 13

1.14 Assembling the fork legs.................................. 14

SUBSTANCES ........................................................... 18

AUXILIARY SUBSTANCES .......................................... 19

SPECIAL TOOLS ........................................................ 20

STANDARDS ............................................................. 22

INDEX .............................................................................. 23

1.1

FORK, TRIPLE CLAMP

Performing a fork service

Condition

The fork legs have been removed.

–

Disassemble the fork legs. (

Remove the spring. (

p. 5)

p. 6)

p. 7)

p. 8)

p. 10)

Disassemble the cartridge. (

Disassemble the piston rod. (

p. 3)

Disassemble the hydrostop unit. (

Disassemble the seal ring retainer. (

Check the fork legs. (

p. 9)

Assemble the seal ring retainer. (

Assemble the hydrostop unit. (

Assemble the piston rod. (

Assemble the cartridge. (

Install the spring. (

Assemble the fork legs. (

p. 13)

p. 14)

p. 11)

p. 12)

201926-01

1.2

Info

Disassembling the fork legs

The steps are identical for both fork legs.

Condition

The fork legs have been removed.

–

Note down the current state of rebound damping

REB

(red adjuster of right fork

leg).

Note down the current state of compression damping

COMP

(white adjuster of

left fork leg).

Fully open the adjusters of the rebound and compression damping.

201699-10

–

Clamp the fork leg in the area of the lower triple clamp.

Clamping stand (T1403S) (

p. 20)

–

Remove screw . Remove adjuster

201700-10

–

Release screw cap

Special socket (T14047) (

p. 20)

Info

The cartridge cannot be taken off yet.

201701-10

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