Question about 2001 KTM EXC 125

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How to seperate upper and lower fork legs - like 4357's ?

I have a 1989 KTM 125 MX with WP 4054 USD forks that need rebuilding . I have done WP 4357's by using a butane torch to seperate the upper and lower legs by expanding the DU bushings above the seal. Will this procedure work OK on the 4054 forks ?

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Remove upper caps, oil and springs. Slide the upper tubes down to the fork foot, remove a red plastic ring with 3 slits clamped around the chrome tube. Now u can slide the tubes apart.

Posted on Aug 27, 2009

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We have a 2016 SX 125. The front suspension has never been right. My rider says it shakes in the air over big jumps. It appears to go away the longer you ride the bike. What could this be?


possible un- even fork fluid in each fork leg. I had those same symptoms on a RM-125, it took myself a while to figure out what it was.

Oct 02, 2016 | 2016 KTM SX 125

1 Answer

How to strip the fork


drain the oil, taking care to hold the spring, remove the upper cap, drain the oil. remove the allen bolt from in the lower end of the fork, pull out on the inner leg forcefully. Do not attempt to dismantle the valving

Aug 04, 2014 | 2004 Honda XR 125 L

1 Answer

Changing fork oil


Remove forks from bike, with each fork remove end cap and drain plug over a bucket drain oil from each fork reinstall drain plug on lower leg, replace oil thought top of the fork to spec, replace end caps and bleed oil from forks

Apr 18, 2014 | 2004 KTM 50 Adventure Senior

1 Answer

Whats the torque specs on the cylinder and head of a 03 ktm 125 sx


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 19, 2011 | 2008 KTM 125 SX

1 Answer

Trying to remove my fork seals from 2005 ktm exc 200. I have the cartrige out but i cannot get the tubes apart or the axle end off. Is there a way the tubes come apart.


Hi, i presume from your thread you have removed the bolt securing the damper to the leg at the axle end, and you are having a problem removing the stancion from the leg, normaly you will have to remove the fork dust seal from the top of the fork leg, you will then expose the main fork seal which will be secured inside the fork leg by a clip,you will need to remove this, as the bushing inside the fork. Is secured to the stancion underneath the fork seal the only way to separate this, once the seal clip is removed, fasten the lower leg in a vice, warning fasten in the axle area and not the tube area to save damage, once secure push the fork tube all the way to the bottom, then pull up sharpley, repaeting this action will give a hammer effect from the inside of the fork, when reasembling before fixing the damper unit replace the fork stanchion, bushing, washer and seal, holding the tube. Upermost will reduce the risk of damage while replacing the seal in the moving area

Apr 04, 2011 | KTM EXC 200 Motorcycles

1 Answer

How to change fork seals on usd forks on kwak meanstreak and how much oil to refill


Having removed the forks, you will need to undo the lower damper bolt first, this is located on the recess inside the fork where. The spindle goes through, this will then alow you to remove the oil from the fork, and the leg will then be free from the stancion moving freely down, if the fork doesnot come apart, you will have to remove the retaining clip from the seal and pull the fork apart sliding the fork leg up the stancion and sharply pulling down on it to pull the seal out, repeat this till theseal comes out, (tip) undo the fork top nut while the forks are still fitted to the bike.

Mar 02, 2011 | 2002 kawasaki VN 1500 Vulcan Meanstreak

1 Answer

09 KTM 250xc-f I am rebuilding the motor and I need the torque specs for this bike can you please help.


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

Sep 28, 2010 | KTM 250 XC Motorcycles

1 Answer

Changing oil in forks


lower for legs there should be a drain bolt for each leg do one side at a time.
Take the top fork cap off be careful the top cap is spring loaded get a pan to catch the oil,remove the drain bolt let it drain.reolace the drain bolt then you can add your new fork oil,check your owners manual for the proper amount and weight oil you need to replace, replace the fork cap.
repeat steps on the other fork.

May 09, 2010 | 1983 Honda XL 125 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

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