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2005-2007 KTM 5018 DCC 5018 SXS 5018 SMR WP SHOCK ABSORBER REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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liter fuel consumption is equivalent to approx. 15 operating hours Check the bearing in the shock absorber top / replace if necessary Check the piston rod on scratches / leakage Check the static sag – before riding Check the spring Check the bump rubber Check the O-ring of the spring retainer / replace if necessary Complete maintenance of the shock absorber 10 hours 65 liter 20 hours 130 liter 30 hours 200 liter 40 hours 260 liter 50 hours 325 liter 60 hours 400 liter 70 hours 455 liter 80 hours 520 liter 90 hours 600 liter 100 hours 665 liter Adjusting the position of the compression and rebound damping Rebound damping: -Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: -Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, high speed: -Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Adjusting the spring preload NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. -Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. -Tighten the lock screw on the adjusting nut. Recommended periodic maintenance and inspection of the 5018 SXS/SMR Shock absorber

KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork

2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

FC Shock Spring Installation Guide

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Filed Under (Tips and Review) by admin on 14-12-2010

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Installation: 1. Remove the fork springs according to the OEM Owner’s Manual. 2. Check/adjust fork oil level and weight according to OEM Specifications. Caution: Most inverted forks will not require the use of any shim washers or spacers. In cases where use is necessary with the twin chamber style fork, the shims must be placed at the bottom of the spring. Most conventional forks (non-inverted) will use shim washers or spacers at the top of the fork spring. 3. Install Factory Connection fork springs and refer to OEM Owner’s Manual for proper assembly procedures. 4. Be sure to double check all fasteners. Note: Most modern day forks require special tools for disassembly and assembly of the components. Examples : Showa 47/49mm Twin Chamber, KYB 48mm Twin Chamber, WP 07 SX Models/SXS Components. Installing fork springs is an intricate process that should be performed with extreme care by a qualified suspension technician. Failure to install the springs correctly could cause damage to one or more components of the fork. This damage, although not readily apparent, could lead to unexpected failure or rider injury. Factory Connection manufactures models specific fork springs. Installation of a Factory Connection spring not designed for your motorcycle may result in unexpected failure and rider injury. Please consult your Factory Connection spring dealer or call Factory Connection directly if you are unsure about a spring/or springs. 1. Factory Connection’s Limited Lifetime Warranty Factory Connection warrants, to the original retail purchaser (“consumer”) who retains ownership of the vehicle on which the suspension spring(s) (“products(s)”) was originally installed, all suspension springs for life against factory defects in material and workmanship (other than defects in finish) when used under normal use and operating conditions. 2. Your Remedy Upon verification of warranty coverage, Factory Connection at its option will replace defective or prematurely worn-out product (s), without charge, or refund the purchase price of the products(s). This is the Consumer’s sole and exclusive remedy for any loss or damage, however arising, due to a nonconformity or defect in the product(s). 3. Warranty Claim Procedure To make claim under this warranty, the consumer should contact the Factory Connection dealer or Factory Connection where the product(s) was purchased. Factory Connection reserves the right to test the returned product(s) to evaluate the nonconformity or possible defect. The Consumer is responsible for all costs of returning the defective or prematurely worn-out product(s) to the Factory Connection dealer as well as all costs for removing the product(s) from and installing the products(s) on the vehicle.

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