Question about 2005 KTM EXC 525 Racing

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Front fork oil change.

Hi,

I trid to take off the top parts of front forks KTM 525 EXC 06
First, I could loosen the top parts but they became very tight and stop at end. Should I keep doing with more power or any other way?
Please let me know.

Thanks.

Kenji

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Kenji,
be careful, the front forks are under a spring. Just keep going and BE CAREFUL.

Posted on Jan 16, 2009

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Make shure that the bike is on a stand other wise the fork top will shoot up and posibly damage the inner thread and also you.

Posted on Jan 10, 2013

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1 Answer

KTM EXC Head Torque Specifications


Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to ensure your issue has been resolved.

KTM Torque settings


  1. Collar screw, front wheel spindle Front axle nut 40Nm 30ft lbs
  2. Brake Caliper front Brake Caliper front Loctite 243 2 19ft lbs
  3. Brake Disk, front Brake disk front Loctite 243 1 11ft lbs
  4. Brake Disk, rear Brake disk rear Loctite 243 1 11ft lbs
  5. Clamping screws, upper fork bridge Top triple clamp 20Nm 15ft lbs
  6. Clamping screws, lower fork bridge Bottom triple clamp 15Nm 11ft lbs
  7. Clamping screws, fork stubs Front axle pinch bolts 10Nm 7ft lbs
  8. Collar nut, rear wheel spindle Rear axle nut 80Nm 59ft lbs
  9. Hex nut swingarm bolt Swingarm nut 100Nm 74ft lbs
  10. Hex collar screw handlebar clamp Upper handlebar clamps 20Nm 15ft lbs
  11. Allen head screw handlebar support Lower handlebar clamps Loctite 243 4 30ft lbs
  12. Shock absorber top Shock absorber top bolt 60Nm 44ft lbs
  13. Shock absorber bottom Shock absorber botton bolt 60Nm 44ft lbs
  14. Sprocket screws Rear sprocket bolts Loctite 243 3 25ft lbs
  15. Ball joint for push rod Rear brake pedal pivot Loctite 243 1 7ft lbs
  16. Engine mounting bolts Engine mounting bolts 45Nm 33ft lbs
  17. Engine brace Engine brace 33Nm 24ft lbs
  18. Screw adjusting ring spring preload Shock preload collar bolt 8Nm 6ft lbs
  19. Spoke nipple Spokes 5Nm 4ft lbs
  20. Other Screws on chassis M6 10Nm 7ft lbs
  21. M8 25Nm 19ft lbs
  22. M10 45Nm 33ft lbs
  23. Other collar nutes on chassis M6 15Nm 11ft lbs
  24. M8 30Nm 22ft lbs
  25. M10 50Nm 37ft lbs
  26. Front Sprocket 44ft lbs

TF

Aug 26, 2011 | 2000 KTM EXC 300

1 Answer

Change front fork seals


Take your front wheel off and stand bike on box or stand. The cable and brake may interfere but leave it on so you don't open up any hydraulic systems Drain the forks. .
You can purchase a tool that looks like a extended deep spark plug socket with a 3/8 inch notch filed across the hex portion. You can also make your own tool out of a 3/8 drive spark plug socket. You can then use a 12 inch long extension and a ratchet with your tool to reach up from the bottom and hold the dampening mechanism while you remove the fork caps and loosen the top nut. (Old Husky Trick) Keep track of the parts order.
Check the manual for fluid capacity and viscosity prior to draining.
Once you have the forks and tubes separated you can remove the seals and wiper with a screw driver or a small puller. Look at the part numbers on the seals and wipers or take them down to a bearing supply house and match them. More than likely SKF or ***. Clean the tubes real good prior to re-assembly. A little grease on the outside of the seals will help reseat them while gently tapping first the seal then the wiper. I use a piece of wood I cut off something. Work your way around gently tapping and keep the seal even. Don't force.
Re-assemble and use lock tite on the internal nut. Don't want wheel coming off mid air.
Thank you for contacting FixYa.
TF

Jun 13, 2011 | 2003 KTM EXC 525 Racing

1 Answer

Does my 93 1100 shadow have oil air in forks and if oil how to add


First of all don't add oil, change it. to drain your oil you need to remove the air tube, remove the front wheel, loosen the allen screw on the bottom of the fork, unscrew the fork top, then remove the fork tube, and turn it over to drain(be careful internal parts of fork will come out)remove parts clean and inspect. Reassemble in reverse order,snug up the screw on bottom, fill top with correct oil qty,cap top, tighten bottom and finish reassembly.

Apr 21, 2010 | 1993 Honda VT 1100 C Shadow

2 Answers

Change oil fork


There is a bit of directions on how to change the oil. I will give you a link to a site that has pictures with step-by-step directions that will work for any bike fork.

http://www.bluepoof.com/motorcycles/howto/svs_fork_oil/

If you have any more questions, feel free to ask..

Nov 25, 2009 | 2004 KTM EXC 200

1 Answer

530 exc spacing between front fork & spacer


front axle installation: looking at the front of the bike:

slide the wheel into position and insert the axle from the left. with axle now through the right hand fork, install nut and tighten the left fork pinch bolts to secure the axle for tightening the nut. tighten the nut to 29.5 ftlbs. and loosen the left pinch bolts. now tighten the right pinch bolts and compress the front suspension while the left (from front) is still loose. now allow suspension to rest naturally and tighten all 4 pinch bolts to 11 ftlbs.
your done.......the axle is tighten against the rotor side and the other fork is then tighten in it's natural position so as not to cause premature seal and bushing failure and increasing stiction.

Sep 27, 2009 | 2008 KTM 530 EXC-R

2 Answers

Refill fork oil


hi mate once the oil is drained you refill with 5w this is the standard oil and when you add the oil pump the dampers up and down until it stops squiling then you can fill it till it is 90mm/9cm from the top of the forks use a ruler and when it hit 9cm pump the forks then measure again if gotten lower top back up then screw the caps back on

Aug 26, 2009 | 2006 KTM 125 EXC

1 Answer

Leaking fork seals


Im replacing the fork seals on my 250yzf just wondering what the oil is thanx gary














Mar 15, 2009 | 2008 KTM 300 EXC-E

2 Answers

How to fill the front suspension on a ktm exc 2001


If you get the sevice manual or contact a dealer to get the correct oil amount for your bike, they need to know the model and year, you have to have the forks off the bike. take the fork caps off, take the springs out compress the upper fork tube all the way and add the specified oil. if they also give you the measured amount from the top that's the best way to get both fork oil levels exact. there is a special tool that you set the oil level in millimeters and it sucks out the oil to the right level, but before you do that step after adding the oil always pull and push on the cartage rod several times to remove air from the cartage tube. you will hear the air coming out and you will feel the changes in the cartage rod as the cartage tube fills up with oil and the air is removed.
something i'm confussed on though is if you replaced a seal you would have had to brake down the fork to replace it. you would have poored the oil into a container, cleaned all the internal parts,and used a fork seal driver to install the new seal. part of your question asks where do i put the oil in? thats in the open end of the fork after you have taken off the fork cap. It sounds to me like you only replaced the dust seal on one fork. that is not going to fix your leaking fork. you need to replace the oil seal thats pressed inside of the top fork tube.

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1 Answer

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and when the forks/bars/tripleclamps are straight the wheel goes towards the right. ii think they are twisted or bent. how much do new forks cost?Loosen your front wheel slightly. Loosen your fork clamp bolts on the triple clamps slighty. Hold the front brake lever. Put one leg on either side of the front wheel to keep it from moving. Use the handlebars to turn the front end back straight. Tighten everything back up using a torque wrench and torqueing to the proper values from your service manual. Go ride and have fun. ,

Nov 10, 2008 | 2004 KTM EXC 250 Racing

1 Answer

Twisted forks


and when the forks/bars/tripleclamps are straight the wheel goes towards the right. ii think they are twisted or bent. how much do new forks cost?Loosen your front wheel slightly. Loosen your fork clamp bolts on the triple clamps slighty. Hold the front brake lever. Put one leg on either side of the front wheel to keep it from moving. Use the handlebars to turn the front end back straight. Tighten everything back up using a torque wrench and torqueing to the proper values from your service manual. Go ride and have fun. ,

Nov 10, 2008 | 2002 KTM EXC 200 GS

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