Assembling The Fork Legs - KTM 250 EXC EU Repair Manual

6 FORK, TRIPLE CLAMP
6.2.23

Assembling the fork legs

Info
When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is mounted
on the corresponding screw cap.
Compression damping side – screw cap with mark COMP, brake caliper holder, white adjuster.
Rebound damping side – screw cap with mark REB, no brake caliper holder, red adjuster.
–
Degrease piston rod
Clamping stand (T14049S) (
–
Screw spring guide
Info
The nut must be firmly tightened against the stop by hand. Do not use a
tool.
–
Mount adjusting tube
202480-11
–
Unclamp the piston rod. Mount the preload spacer(s).
Preparatory work
–
Assemble the hydrostop unit. (
Main work
–
Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
–
Mount special tool.
Protecting sleeve (T1401) (
–
Lubricate and mount dust boot
201714-10
Lubricant (T511) (
Info
Always change the dust boot, seal ring, lock ring and support ring.
Mount the sealing lip with the spring expander facing downward.
–
Slide on lock ring
–
Lubricate and slide on seal ring
Lubricant (T511) (
Info
Mount with the sealing lip facing down and the open side facing up.
–
Slide on support ring
–
Remove the special tool.
–
Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush-
ings and lubricate them.
Fork oil (SAE 4) (48601166S1) (
201715-10
and clamp in the vise.
8
p. 280)
all the way on.
bk
.
bl
p. 44)
p. 278)
.
1
p. 270)
.
2
.
3
p. 270)
.
4
p. 268)
47