Telescopic Fork Maintenance (50 Mini Adventure); Changing The Telescopic Fork Oil (50 Mini Adventure) - KTM 50 SENIOR ADVENTURE 2006 Owner's Manual

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MAINTENANCE WORK ON CHASSIS AND ENGINE

Telescopic fork maintenance (50 Mini Adventure)*

The telescopic fork must be serviced at least once a year:
Jack up the motorcycle by the frame to take the weight off the front wheel.
Remove the front wheel and the brake cable guide.
Measure the projection of the fork legs at the upper fork stabilizer and make
a note of the measurement.
1 Release the clamp screws [1] at the triple clamps and pull the fork legs down-
wards out of the triple clamps.
1
1
Clamp the fork leg into a vise (use protective jaws) and remove the
2
plugs [2].
Take the preload spacer and the spring out of the fork tube.
Remove screws [3] at the underside of the slider tubes and pull the fork tubes
out of the slider tubes.
Remove the dust scrabbers [4].
20
Thoroughly clean all parts and check for wear.
3 4
Grease gaskets and springs and reassemble the telescopic fork.
Tighten the screws at the underside of the slider tubes to 30 Nm.
Fill in fork oil and assemble the fork (see below).
Insert the fork legs into the triple clamps (projection as previously noted) and
tighten the clamp screws to 20 Nm (top) and 10 Nm (bottom).
Mount the front wheel (see chapter: mounting the front wheel).

Changing the telescopic fork oil (50 Mini Adventure) *

Remove front wheel and fork legs (see above).
min. 2 mm
Remove plugs, preload spacers and springs.
Drain the fork oil into an appropriate container.
Clean the dust scrabbers.
2
4
3
Pour 170 cm 3 SAE 7.5 fork oil into each fork tube.
Slide the fork tube all the way into the slider tube.
Adjust the air-chamber length A to 110 mm (4.5 in) by extracting or
A
adding fork oil.
Insert springs and pretensioning sleeves into the fork tube.
Check O-rings, grease and mount plugs.
Mount fork legs and front wheel (see above).
Mount brake control cable and brake cable guide.
Adjust the cable control on the front brake.