KTM 300 EXC, Repair Manual

Page: 47 / 289

6 FORK, TRIPLE CLAMP
45
201790-10
–
Degrease the piston rod.
–
Clamp the piston rod with the special tool.
Clamping stand (T14049S) ( p. 280)
–
Lubricate the O-ring. Mount valve needle
1
in the piston rod.
Lubricant (T158) ( p. 270)
201791-10
–
Mount spring
2
.
–
Mount and tighten adapter
3
with spring
4
and washer.
Guideline
Adapter of piston rod M6x0.5 12 Nm (8.9 lbf ft)
201730-10
–
Position the spring.
–
Mount the compression shim stack
5
with the smaller washers facing downward.
201792-10
–
Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper.
–
Clean the piston.
–
Lubricate the piston ring.
Fork oil (SAE 4) (48601166S1) ( p. 268)
–
Mount the piston with chamfer
A
facing down.
201732-11
–
Mount the rebound shim stack
6
with the smaller washers facing upward.
201793-10
–
Press the piston downward against the spring.
The piston should not squeeze the shims.
–
Position valve
7
in the hydrostop needle
8
. Mount and tighten the hydrostop nee-
dle.
Guideline
Hydrostop needle on piston rod M6x0.5 7 Nm (5.2 lbf ft)
Info
A
–
silver hydrostop needle on compression damping side.
B
–
red hydrostop needle on rebound damping side.