Assembling The Hydrostop Unit; Assembling The Piston Rod - KTM 250 EXC EU Repair Manual

6 FORK, TRIPLE CLAMP
6.2.20

Assembling the hydrostop unit

Info
The steps are identical for both fork legs.
6.2.21

Assembling the piston rod

Info
The steps are identical for both fork legs, except for the hydrostop needle and valve.
–
Mount and grease seal ring
Lubricant (T158) (
–
Mount and grease O-ring
Lubricant (T158) (
–
Position pilot bushing support
201800-10
–
Mount and grease O-ring
Lubricant (T158) (
–
Mount washer
–
Mount shim stack
201783-10
–
Mount the new O-ring on hub
–
Mount the hub with washers
Info
It is possible that only one or no washer is present.
–
Mount and tighten adapter
Guideline
Hydrostop unit adapter
201784-10
–
Mount shim stack
–
Mount and tighten sleeve
Guideline
Hydrostop unit sleeve
201785-10
–
Check distance
Guideline
Hydrostop distance
Hydrostop length
» If the dimensions are out of tolerance:
–
Add or remove washers
201975-10
.
1
p. 270)
.
2
p. 270)
.
3
.
1
p. 270)
.
2
with the smaller washers facing downward.
3
.
4
.
5
.
6
with the smaller washers facing downward.
7
.
8
and total length of the hydrostop.
A B
.
5
M6x0.5 7 Nm (5.2 lbf ft)
M6x0.5 7 Nm (5.2 lbf ft)
≥ 1.5 mm (≥ 0.059 in)
108.5... 109.5 mm (4.272...
4.311 in)
44