KTM 300 EXC, Repair Manual

Page: 27 / 289

6 FORK, TRIPLE CLAMP
25
Preparatory work
–
Check the fork legs. ( p. 21)
–
Assemble the cartridge. ( p. 23)
–
Assemble the compression damping fitting. ( p. 22)
200669-10
Main work
–
Clamp in the inner tube with the axle clamp.
Guideline
Use soft jaws.
–
Install the special tool.
Protecting sleeve (T1401) ( p. 278)
–
Grease and slide on dust boot
1
.
Lubricant (T511) ( p. 270)
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
2
.
–
Grease and slide on seal ring
3
.
Lubricant (T511) ( p. 270)
Info
The sealing lip should face downward and the open side upward.
–
Slide on support ring
4
.
–
Remove the special tool.
200670-10
–
Roughen, clean, and grease the edges of the sliding bushings using 600 grit sand-
paper.
Fork oil (SAE 4) (48601166S1) ( p. 268)
200671-10
–
Slide on lower sliding bushing
5
.
–
Mount upper sliding bushing
6
.
Info
Gently pull them apart without using any tool.
201356-10
–
Slide on the outer tube.
–
Warm up the outer tube in the lower sliding bushing area of
A
.
Guideline
50 °C (122 °F)
–
Hold the lower sliding bushing with the longer shoulder of the special tool.
Assembly tool (T1402S) ( p. 279)
–
Press the outer tube all the way in.