wp fork information

Index

Page WP4357 WP4860 Discs Springs Weight Valving Shims Husa Calcs Graph Bearings

The valving page calculates shim stack sizes, float etc more accurately than conventional measurement, there are columns for your valving experiments The calcs and graph compares damper fork spring rates to cartridge forks and machine weights to give an understanding of the differences

Page 1

Index

IndexDescription WP 4357 Year Model Parts Information WP 4860 Year Model Parts Information KTM Disc Specs (From metalgear.com.au) Available Spring Information 4375 & 4860 Machine Weight Comparison GS / GS YZ / GS WP Valving Calculations Page 640Adv / 640Adv Mod / GS KTM Shim Part Numbers Alpha & Numeric Husaberg Valving from (Husaberg.org) Machine Weight vs Fork & Spring Comparison Graph of Spring Rate Calculations Page General Bearing Information Table

See Notes below

The valving page calculates shim stack sizes, float etc more accurately than conventional measurement, there are columns for your valving experiments The calcs and graph compares damper fork spring rates to cartridge forks and machine weights to give an understanding of the differences

Page 2

WP 4357

Part No's extracted from spare parts manuals

S=Standard E=Enduro

X=Option / As Required SM=SuperMotard

Models with 4357MXMA Forks

2000 to 2002 - 250, 300, 380 SX, MX, EX 2000 to 2002 400/520 (4860 optional in 2002) 2000 to 2005 620/625 SX 2000 to 2005 640 Enduro Qty Cost Nov 09 US Cost Nov09 Aus Wire Rate Length Dia mm n/mm mm 250-380 SX/MX 2000-02 400/520 SX/MX 2000-02 295 260 2 2 1 1 1 1 1 1 1 1 1 1 $16.99 $17.99 $47.99 $45.99 $140.99 $173.99 $7.99 $6.99 $76.99 $15.99 $196.99 $186.99 $39.18 $35.44 $105.42 $108.18 $260.91 $250.45 $12.63 $12.12 $133.03 $31.44 $305.69 $400.88 Fits all SX/EX/MX Fits all SX/EX/MX Fits all SX/EX/MX Fits all SX/EX/MX new P/N all models All models 2000-10 All models 2000-10 was 501.01.033.200 was 546.01.084.100 was 590.01.132.020 S S S S S S S S S S S S S S S S S S 620/625 SX 2000-05 295 260

Dia No

Part No

Description

Front Suspension Travel Front Disc 38 38 39 39 34 34 86 84 33 82 32 32 503.01.038.000 590.01.038.200 590.01.039.000 590.01.039.100 584.01.034.318 590.01.234.020 542.01.086.000 546.01.184.000 548.01.033.200 546.01.084.200 590.01.132.220 584.01.032.118 Handlebar Clamp D=22mm Handlebar Clamp D=28mm Handlebar Support D=22mm Handlebar Support D=28mm Top Triple Clamp x=18,d=54 Top Triple Clamp x=20,d=54 Steering Head Cover Steering Head Gasket Top Fork Tube L=244 EXC O-Ring Support w sealing lip Bot Triple Clamp x=20,d=54 Bot Triple Clamp x=18,d=57

Dia No

Part No

Description

Qty

Cost Nov 09 US

Cost Nov09 Aus

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05

Parts Breakdown for item 4 below 1 2 3 5 6 7 8 9 10 11 4860.0020s 4860.0016 4860.0018 4054.0603 4860.0028 4860.0044 4860.0058 4860.0009 4860.0043 4860.0019 Screw Cap m51x1.5 O-Ring 48x2 Knob Rebound Adjuster Steel Ball D=3mm Spring D=2.9 L=7.9 O-Ring 6x1.5 Vent Screw m4x6 O-Ring 3.7x1.6 O-Ring 12x1.5 Holder Adj Tube D=4mm 2 2 2 8 4 2 2 2 2 2 $47.99 $4.99 $0.99 $2.99 $0.99 $0.99 $0.99 $1.99 $2.99 $78.66 $4.17 $7.78 $1.93 $3.69 $1.93 $1.93 $1.93 $3.75 $5.13

95 95 4 37 37 37 37 37 30 30 33 33 33

4860.0074s 4860.0075s 4860.0020s1 4860.0036 4860.0037 4860.0038 4860.0039 4860.0053 4860.0014 4860.0094 4860.0003 4860.0150 4860.0189

Preload Adjuster Preload Adjuster m51x1.5 Screw Cap m51x1.5 Spacer 42x26.5x2.5 Spacer 42x26.5x5 Spacer 42x26.5x10 Spacer 42x26.5x1.5 Spacer 42x26.5x1.5 Adjust Tube L=512mm Adjust Tube L=492mm Needle Rebound Needle Rebound Needle Rebound

2 2 2 2 2 4 2 2 2 2 2 2 2

$150.99 $330.77 $116.99 $165.58 $47.99 $78.66 $6.99 $11.87 $6.99 $11.87 $6.99 $11.87 $6.99 $13.99 $14.99 $6.99 $22.99 $30.99 $11.87 $23.18 $23.18 $10.83 $42.01 $42.63

Price is for a pair

X S X/? S X/S X/S X/S S01 S02 S S01 S02

X S S 03-05 S 03-05

now 4860.0053 was 4860.0039 512 492

S01 S S01 S 02

S 03-05 S SM S-01 S-02 S 03-05

Dia No 34 35 24 31 31 31 31 38 38 38 38 38 38 38 39 42 42 43 43 44 44 44 44 45 45 45 47 47

Part No

Description

Qty

4860.0046 4860.0033 4357.0142S1 4860.0093 4860.0023 4860.0250 4860.0408 9501.0010s 9501.0001s 9501.0002s 9501.0003s 9501.0004s 9501.0012s 9501.0022s 4357.0131 4860.0132s 4860.0200s 4681.0651 4860.0239 4860.0015 4860.0178 4860.0192 4860.0403 4860.0025 4860.0151 4860.0203 4860.0059 3548.0377

O-Ring 3x1.5 Spring Rebound Needle Hydr Stop D=27.5 CPL05 Piston Rod D=14m 11x1 Piston Rod D=14m 11x1 Piston Rod D=14m 11x1 Piston Rod D=14m 11x1 Spring Spring Spring Spring Spring Spring Spring Interm Ring 26,2x38,5x3 Screw Sleeve m29,3x1 Screw Sleeve m29,3x1 DU Bush 14x16x12 O-Ring 8x1.25 Rebound Spring D=14.6 Rebound Spring D=14.6 Rebound Spring D=15 Rebound Spring D=15 C12 Tap Rebound Tap Rebound Tap Rebound D=3 Spring Check Valve D=0.25 Spring Check Valve D=0.5

2 2 2 2 2 2 2

Cost Nov 09 US $1.99 $12.99 $53.99 $62.99

2 2 2 2 2 2 2 2 2 2 2 2 2 2

$156.99 $156.99 $156.99 $156.99 $156.99 $156.99 $156.99 $13.99 $47.99 $68.99 $6.99 $2.99 $18.99 $18.99 $36.99 $26.99 $25.99 $36.99 $7.99 $2.99

Cost Wire Rate Length Nov09 Dia Aus mm n/mm mm $3.75 $20.52 4 $81.76 200 $90.52 526 $90.52 546 $114.57 546 $125.25 546 $223.61 4.6 3.6 $223.61 4.75 3.8 $223.61 4.75 4 $223.61 4.9 4.2 $223.61 4.9 4.4 $223.61 4.9 4.4 $223.61 5 5 $23.93 $90.52 39 $113.74 65 $9.11 ?? $3.50 ?? $29.06 22 $30.59 75 $22.23 34.5 $40.34 34.5 $43.33 $40.91 $48.53 $17.28 $4.14

250-380 SX/MX 2000-02 S S S S-01

400/520 SX/MX 2000-02 S S S S01 S02 X X X S X

620/625 SX 2000-05 S S S SM S 01-02 S 03-05 X X X S X X SM S S 01-02 S 03-05 S-01 S S 01-02 S 03-05

X X X S X X S S-01 S-01 S-01

S S S S

S-01 S 02 S-01

S01 S02 S01 S02

S-01 S-02 S 03-05 S-01 S 02-05

Dia No 49 49 49 49 49 49 49 49 52 51 50 55 12 12 13 15 15 16 17 17 18 19 19 22 22 23 23 58

Part No

Description

Qty

4054.1408 4054.1414 4054.1416 4357.0120 4860.0062 4860.0068 4860.0215 4860.0216 4860.0042 4860.0060 4054.0486 4357.0125 4357.0211 4357.0099 4357.0019 4357.0204 4357.0092 4357.0140 4357.0201 4357.0008 4357.0094 4357.0202 4357.0020 4357.0203 4357.0145 4357.0221 4860.0081

Shim 6x8.0x0.3 Shim 6x8.0x0.1 Shim 6x8.0x0.3 Shim 8x18x0.1 Check Valve 8x24x0.1 Check Valve 8x18x0.1 Check Valve 8x20x0.1 Check Valve 8x22x0.1 Piston Rebound D=27.7 Piston Ring 5x1x84 Shims as required Nut Rebound m6x0.5 Outer Tube D=54/57 Outer Tube D=54/57 Guiding Ring D=53mm DU-Bush 43x47x20 DU-Bush 43x47x12 Daido Support Ring 45x52.5x1.5 Oil Seal Ring 43x53.15x9.5 Oil Seal Ring 43x52.9x9.5 Lock Washer SB53 Dust Stripper 43mm Dust Stripper 43x53.4x11.8 DU-Bush 43.8x43x20 DU-Bush 42x44x20 Inner Tube D=43mm Inner Tube D=43mm Tube 29.3x1x390 D=8.5

2 2 2 2 8 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Cost Nov 09 US $1.99 $1.99 $1.99 $8.99 $3.99 $3.99 $5.99 $5.99 $48.99 $4.99

Cost Nov09 Aus $3.75 $3.75 $3.75 $10.76 $5.32 $5.32 $5.32 $5.69 $71.81 $9.09

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02 X X

400/520 SX/MX 2000-02 X X X02 S

620/625 SX 2000-05 X X

S

S S See Shim List below S S 01-02 S S 01-02 S S S S

S S S S S S S S S S S

S S S S S S S S 01-02 S 03-05 S S 01-02 S 03-05 S S 01-02 S 03-05 S S 01-02 S 03-05 S 01-02 S 03-05 S 01-03 S-04/05 S

$4.99 $4.69 $383.99 $575.92 $473.99 $712.70 $2.99 $4.79 $24.99 $45.22 $17.99 $49.97 $3.99 $6.74 $58.27 $21.99 $33.40 $2.99 $4.79 $35.08 $23.99 $29.68 $23.99 $46.96 $30.99 $49.97 $492.36 $413.99 $567.86 $91.99 $115.33

577 577 2001-2 Models 2003 onwards now 4357.201

now 4357.202 2001-2 Models 2003 onwards 585 585 390

S S

S S

Dia No 58 59 60 60 60 61 61 62 62 63 63 64 64 70 70 71 72 50 69 69 69 82 99

Part No

Description

Qty

4860.0140 4357.0023 4357.0124 4357.0124s 4357.0207s 4357.0123 4357.0123s 0015.080253 5060.0061 4054.1241 4860.0163 4054.1278 4860.0202 4860.0061 4054.1408 4860.0047 4861.1499 4860.0027s 4860.0152s 4860.0152s1 4860.0141 R510

Tube 29.3x1x385 ALU O-Ring 41x2 Axle Clamp L/S 260 M8 00 Axle Clamp L/S 04 Axle Clamp L/S 04 Axle Clamp R/S 260 M8 00 Axle Clamp R/S 04 HH Collar Screw 8x25 HH Collar Screw 8x30 Check Valve Nut 6x0.5 Check Valve Nut 6x0.5 D=2 Spring Check Valve D=0.5 Spring Check Valve D=0.5 Check Valve 8x24x0.4 Shim 6x8x0.3 Piston Compression D=27.9 O-Ring 21x2 Shims as required Tap Compression Tap Compression D=35mm Tap Compression D=35mm Rubber Cap Repair Kit 4357 MXMA

2 2 1 1 1 1 1 4 4 2 2 2 2 2 2 2

2 2 2 1

Cost Cost Wire Rate Length Nov 09 Nov09 Dia US Aus mm n/mm mm $85.99 $158.54 385 $2.99 $4.79 $223.99 $409.07 $266.99 $406.50 $312.81 $313.39 now 4357.0123s $323.60 $4.06 $7.96 now 0015080303 $7.99 $10.35 $13.99 $16.15 $3.99 $6.74 $2.99 $3.75 $3.99 $5.32 $1.99 $3.75 $48.99 $71.81 $1.99 $3.75 See Shim List below $45.99 $79.33 $62.99 $81.88 $62.99 $81.88 $2.99 $4.36 $333.02

250-380 SX/MX 2000-02 S S

400/520 SX/MX 2000-02 S S01 S02

620/625 SX 2000-05 SM S S 01-02 S 03-05 S 01-02 S 03-05 S-04/05 S-03 S 01-02 S 03-05 S 01-02 S 03-05 S S S S 00/01 S 02 S 03-05 S02-05 Fits

S S S S S S S S S 00/01 S 02 S S S S X02 S S S 00/01 S 02 S02

81 73

Parts Breakdown for item 69 Above 4860.0004 Copper Washer 29.5x33.5x1 3548.0320 O-Ring 24x2

2 2

$1.99 $2.99

$2.84 $5.28

S S

S S

S S

Dia No 74 74 75 75 75 80 5 6 76 79

Part No

Description

Qty

4860.0027 4860.0152 4860.0035 4860.0153 4860.0190 4860.0034 4054.0603 4860.0028 4860.0049 4860.0051

Tap Compression Tap Compression Needle Compression m10x1 Needle Compression m10x1 Needle Compression m10x1 Compression Adj Screw Steel Ball D=3mm Spring D=2.9 L=7.9 O-Ring 8x2 Lock Washer RB12

2 2 2 2 2 2 8 4 2 2

Cost Nov 09 US $33.99 $34.99 $5.99 $5.99 $11.99 $7.99 $0.99 $2.99 $3.99 $1.99

Cost Wire Rate Length Nov09 Dia Aus mm n/mm mm $67.31 now 4860.0586 @07 $67.31 now 4860.0586 @07 $8.35 $9.32 $15.46 $13.48 $1.93 $3.69 $11.71 $2.19

250-380 SX/MX 2000-02 S 00/01 S 02 S 00/01 S 02 S S S S S

400/520 SX/MX 2000-02 S 00/01 S 02 S 00/01 S 02 S S S S S

620/625 SX 2000-05 S 00/01 S 02-05 S 00/01 S 02 S 03-05 S S S S S

Notes 1 2 3 4 5 6 Items 4 & 69 New combined part No's for compression & rebound adjusters shown as individual parts on early diagrams The number of spacers at top of forks (item 36/37) vary between year models adjusting preload & spring length variations Discrepancies between diagrams for Item 42 Screw Sleeve, it has a bush & some diagrams split the bush to a separate item 43 Item 43 - O-Ring 8x1.25 shown on some diagrams not all unsure if needed or is a diagram error 640LC Super Motard 03 onwards moved to WP4860 Forks Enduro parts lists show both 4357 & 4860 2003-06 online 4860 only KTM have different prices for universal 4357 & 4860 forks & prices can be lower ordering under the generic part number

Available Shim List 49 49 49 4054.1414 4054.1408 4054.1416 4054.1417 Shim 6x8.0x0.1 Shim 6x8.0x0.3 Shim 6x8.0x0.3 Shim 6x8.5x0.1 $1.99 $1.99 $1.99 $1.99 $3.75 $3.75 $3.75 $4.56

Dia No

Part No

Description

Qty

50

50

50 50 50

50 50 50 50 50

50 50

4054.0425 4054.0418 4054.0426 4054.0449 4054.0419 4054.0423 4054.0427 4054.045 4054.1404 4054.1405 4054.1403 4860.0217 4054.0447 4054.1383 4860.0323 4054.1406 4860.0324 4054.1402 4054.0417 4054.1391 4054.0400 4054.0404 4054.0408 4054.0412 4054.1393 4860.0325 4860.0326 4054.0401

Shim 6x8.5x0.2 Shim 6x9.0x0.1 Shim 6x9.0x0.2 Shim 6x9x0.3 Shim 6x9.5x0.1 Shim 6x9.5x0.15 Shim 6x9.5x0.2 Shim 6x9.5x0.3 Shim 6x10x0.1 Shim 6x10x0.15 Shim 6x10x0.2 Shim 6x10x0.25 Shim 6x10x0.3 Shim 6x11x0.1 Shim 6x11x0.1 Shim 6x11x0.15 Shim 6x11x0.15 Shim 6x11x0.2 Shim 6x11x0.25 Shim 6x11x0.3 Shim 6x12x0.1 Shim 6x12x0.15 Shim 6x12x0.2 Shim 6x12x0.25 Shim 6x12x0.3 Shim 6x13x0.1 Shim 6x13x0.15 Shim 6x14x0.1

Cost Nov 09 US $2.99 $9.99 $2.99 $2.99 $2.99 $16.99 $2.99 $1.99 $2.99 $2.99 $2.99 $3.99 $1.99 $2.99 $7.99 $3.99 $7.99 $2.99 $2.99 $2.99 $2.99 $3.99 $3.99 $3.99 $7.99 $7.99 $2.99

Cost Nov09 Aus $6.56 $17.19 $6.56 $3.75 $6.56 $26.55 $6.56 $3.42

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05

Also 4054.0470 Was 4054.0450

$4.17 $3.75 $4.56 $8.83 $29.69 $8.83 $4.56 $6.56 $4.56 $4.56 $5.32 $4.69 $4.56 $4.56 $8.83 $8.83 $4.56

x

Dia No 50

Part No

Description

Qty

50 50 50 50 50 50 50 50 50 50 50

50

50

4054.0405 4054.0409 4054.0413 4860.0327 4860.0328 4054.0402 4054.0406 4054.0410 4054.0414 4860.0329 4860.0330 4054.0403 4054.0407 4054.0411 4054.0415 4054.0494 4860.0331 4860.0065 4860.0069 4860.0095 4860.0096 4860.0332 4860.0064 4860.0097 4860.0098 4860.0099 4860.0333 4860.0063

Shim 6x14x0.15 Shim 6x14x0.2 Shim 6x14x0.25 Shim 6x15x0.1 Shim 6x15x0.15 Shim 6x16x0.1 Shim 6x16x0.15 Shim 6x16x0.2 Shim 6x16x0.25 Shim 6x17x0.1 Shim 6x17x0.15 Shim 6x18x0.1 Shim 6x18x0.15 Shim 6x18x0.2 Shim 6x18x0.25 Shim 6x18x0.4 Shim 6x19x0.1 Shim 6x20x0.1 Shim 6x20x0.15 Shim 6x20x0.2 Shim 6x20x0.25 Shim 6x21x0.1 Shim 6x22x0.1 Shim 6x22x0.15 Shim 6x22x0.2 Shim 6x22x0.25 Shim 6x23x0.1 Shim 6x24x0.1

Cost Nov 09 US $2.99 $2.99 $2.99 $7.99 $2.99 $2.99 $3.99 $2.99 $7.99 $7.99 $2.99 $4.99 $2.99 $2.99 $4.99 $4.99 $2.99 $3.99 $3.99 $3.99 $7.99 $2.99 $3.99 $3.99 $3.99 $7.99 $2.99

Cost Nov09 Aus $4.56 $4.56 $4.56 $8.83 $29.69 $4.56 $4.56 $4.15 $4.56 $8.83 $8.03 $4.56 $4.69 $4.56 $4.56 $6.45 $8.83 $4.56 $4.69 $4.56 $4.56 $8.83 $4.56 $4.56 $4.56 $4.56 $8.83 $4.56

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05

Dia No

Part No

Description

Qty

4860.0100 4860.0101 4860.0102 4054.0774 4860.0139 4860.0116 4860.0480 4860.0357 4860.0346 4860.0352 4860.0351 4860.0213 4860.0385 4860.0214 4860.0350 4860.0555 4860.0068 4357.0120 4054.0477 4860.0215 4860.0216 4860.0384 4860.0062 4860.0061 4860.0212

Shim 6x24x0.15 Shim 6x24x0.2 Shim 6x24x0.25 Shim 6x18x0.1 Delta Shim 6x22x0.1 Delta Shim 6x24x0.1 Delta Shim 8x10x0.20 Check Valve 8x11x0.1 Shim 8x11x0.2 Check Valve 8x11x0.2 Check Valve 8x12x0.1 Shim 8x14x0.10 Shim 8x14x0.25 Shim 8x16x0.1 Check Valve 8x16x0.15 Shim 8x16x0.20 Check Valve 8x18x0.1 Shim 8x18x0.1 Shim 8x18x0.4 Check Valve 8x20x0.1 Check Valve 8x22x0.1 Check Valve 8x22x0.3 Check Valve 8x24x0.1 Check Valve 8x24x0.4 Pressure Ring 20x16.25x0.20

Cost Nov 09 US $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 2.99 5.99 7.99 $4.99 $4.99 2.99 $5.99 $4.99 19.99 3.99 $8.99 3.99 $5.99 $5.99 $5.99 $3.99 3.99

Cost Nov09 Aus $4.15 $4.56 $4.56 $5.32 $5.32 $5.32 4.55 5.32 8.34 $5.32 $5.32 $5.88 $5.69 $5.88 $8.34 $55.74 $5.32 $10.76 $6.45 $5.32 $5.69 $5.69 $5.32

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05

50 50

Was 4860.0067 Was 4860.0066

49 49

49 49

49 49 49 49

50

From 4860

Dia No

Part No

Description

Qty

Cost Nov 09 US

Cost Nov09 Aus

Wire Rate Length Dia mm n/mm mm

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05

Consumable Parts Dia No 2 7 9 10 34 39 43 43 51 13 15 16 17 18 19 22 59 71 72 Part No 4860.0016 4860.0044 4860.0009 4860.0043 4860.0046 4357.0131 4681.0651 4860.0239 4860.0060 4357.0099 4357.0019 4357.0092 4357.0201 4357.0008 4357.0202 4357.0020 4357.0023 4860.0047 4861.1499 Description O-Ring 48x2 O-Ring 6x1.5 O-Ring 3.7x1.6 O-Ring 12x1.5 O-Ring 3x1.5 Interm Ring 26,2x38,5x3 DU Bush 14x16x12 O-Ring 8x1.25 Piston Ring 5x1x84 Guiding Ring D=53mm DU-Bush 43x47x20 Support Ring 45x52.5x1.5 Oil Seal Ring 43x52.9x9.5 Lock Washer SB53 Dust Stripper 43x53.4x11.8 DU-Bush 43.8x43x20 O-Ring 41x2 Piston Compression D=27.9 O-Ring 21x2

Cost Qty Nov 09 US 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Cost Nov09 Aus $4.17 $1.93 $1.93 $3.75 $3.75 $23.93 $9.11 $3.50 $9.09 $4.79 $45.22 $6.74 $33.40 $4.79 $29.68 $46.96 $4.79 $71.81 $3.75

Notes Protech Fork Cap

Source FluidS $1.30 $0.31 $0.47 $0.84 $0.29

$0.99 $0.99 $1.99 $1.99 $13.99 $6.99 $2.99 $4.99 $2.99 $24.99 $3.99 $21.99 $2.99 $23.99 $23.99 $2.99 $48.99 $1.99

Damper $18.22 $18.18 2001-2 Models was 4357.0140 was 4357.0094 2001-2 Models $59.36 $93.92 $90.44

$1.77 $0.77

Dia No 81 73 76 79

Part No

Description

Qty

4860.0004 3548.0320 4860.0049 4860.0051

Copper Washer 29.5x33.5x1 O-Ring 24x2 O-Ring 8x2 Lock Washer RB12 Total

2 2 2 2

Cost Nov 09 US $1.99 $2.99 $3.99 $1.99

Cost Nov09 Aus $2.84 $5.28 $11.71 $2.19

Wire Rate Length Dia mm n/mm mm Compression Valve

250-380 SX/MX 2000-02

400/520 SX/MX 2000-02

620/625 SX 2000-05 $1.05 $0.36

$204.78 $335.11

$280.12

$7.16

12 12 13 15 15 16 17 17 18 19 19 22 22 23 23

4357.0125 4357.0211 4357.0099 4357.0019 4357.0204 4357.0092 4357.0140 4357.0201 4357.0008 4357.0094 4357.0202 4357.0020 4357.0203 4357.0145 4357.0221

Outer Tube D=54/57 Outer Tube D=54/57 Guiding Ring D=53mm DU-Bush 43x47x20 DU-Bush 43x47x12 Daido Support Ring 45x52.5x1.5 Oil Seal Ring 43x53.15x9.5 Oil Seal Ring 43x52.9x9.5 Lock Washer SB53 Dust Stripper 43mm Dust Stripper 43x53.4x11.8 DU-Bush 43.8x43x20 DU-Bush 42x44x20 Inner Tube D=43mm Inner Tube D=43mm

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

640LC4 Enduro 2000-05 270 300

S S S S S S

640LC4 Enduro 2000-05

X S S 03-05 S 03-05 S-04/05 S-01 S-05 S SM S-01 S-02 S 03-05

640LC4 Enduro 2000-05 S S S SM S 01-03 S-04 S-05 X X X S 02-05 X S-01 SM S S 01-02 S 03-05 S-01 S S01-SM S 01-02 S -03 S 04-05 S-01 S-02 S 03-05 S-01 S 02-05

640LC4 Enduro 2000-05 X X S-03/05 S S 03-05 S 03-05 S S S S 01-02 S 03-05 S S 01-02 S 03-05 S S 01-02 S 03-05 S S 01-02 S 03-05 S 01-02 S 03-05 S 01-03 S-04/05 S

640LC4 Enduro 2000-05 SM S S 01-02 S 03-05 S 01-03 S-04/05 S-04/05 S-03 S 01-02 S 03-05 S 01-03 S-04/05 S S S S 00/01 S 02 S 03-05 S02-05 Fits

S S

640LC4 Enduro 2000-05 S 00/01 S 02-05 S 00/01 S 02 S 03-05 S S S S S

640LC4 Enduro 2000-05

640LC4 Enduro 2000-05

640LC4 Enduro 2000-05

640LC4 Enduro 2000-05

T4B

O-Rings KTM $8.34 $3.86 $3.86 $7.50 $7.50

$49.00

$9.58 $7.50

640LC4 Enduro 2000-05 $10.56 $23.42

$49.00

$82.12

WP 4860

Part No's extracted from spare parts manuals

S=Standard

X=Option / As Required

Models with 4860MXMA Forks

2003 onwards - 250, 300, 380 SX, MX, EX 2003 onwards 450/525 2001 to 2005 640 Adventure 2003 onwards 950 & 990 Adventure Qty Cost Cost Wire Rate Length 400-520 450/525 640 Nov 09 Nov09 Dia SX SX/EX Adv US Aus mm n/mm 2002 2003-4 2001-5 295 295 950 990 Adv/S A, E, S 2003-5 2007 215 ?

Dia No

Part No

Description

Suspension Travel

270/275 230/265 05210

34 34 34 13 86 84 33 33 19 82 32 32 18 32

590.01.034.120 584.01.034.218 584.01.034.318 600.01.034.018 542.01.086.000 546.01.184.000 501.01.034.100 501.01.033.100 600.01.033.000 546.01.084.200 582.01.032.018 582.01.032.118 600.01.032.018 590.01.132.120

Top Triple x=20 d=54 SX Top Triple x=18 d=54 Adv Top Triple x=18 d=54 Adv Top Triple x=18 d=54 Steering Head Cover Steering Head Gasket Top Fork Tube '91 Fork Tube '91 Fork Tube LC8 Adv '03 O-Ring Support w sealing lip Bot Triple x=18 d=60 Adv Bot Triple x=18 d=60 Adv Bot Triple x=18 d=60 Bot Triple x=20 d=60 SX

1 1 1 1 1 1 1 1 1 1 1 1 1 1

$173.99 $164.99 $140.99 $193.99 $7.99 $6.99 $76.99 $65.99 $15.99 $191.99 $214.99 $209.99

$250.45 same as 4357 forks $260.91 $260.91 $331.40 $12.63 All models 2000-10 $12.12 All models 2000-10 244 $117.24 244 $120.20 ? $31.44 was 546.01.084.100 $448.46 $448.46 $426.21 $382.91 was 590.01.032.120

S

S S 01/2 S 03-5

S S S

S S S

S S S

S S S

S S

S

S

S S 01/2 S 03

S S

S

S S S

Dia No

Part No

Description

Qty

Cost Cost Wire Rate Length 400-520 450/525 640 Nov 09 Nov09 Dia SX SX/EX Adv US Aus mm n/mm 2002 2003-4 2001-5

950 990 Adv/S A, E, S 2003-5 2007

Parts Breakdown for item 4 below 1 2 3 5 6 7 8 9 10 11 4860.020s 4860.0016 4860.0018 4054.0603 4860.0028 4860.0044 4860.0058 4860.0009 4860.0043 4860.0019 Screw Cap m51x1.5 O-Ring 48x2 Knob Rebound Adjuster Steel Ball D=3mm Spring D=2.9 L=7.9 O-Ring 6x1.5 Vent Screw m4x6 O-Ring 3.7x1.6 O-Ring 12x1.5 Holder Adj Tube D=4mm 2 2 2 8 4 2 2 2 2 2 $47.99 $4.99 $0.99 $2.99 $0.99 $0.99 $0.99 $1.99 $2.99 $78.66 $4.17 $7.78 $1.93 $3.69 $1.93 $1.93 $1.93 $3.75 $5.13

85 4 37 37 37 37 30 30 30 30 30 33 33

4860.0075s 4860.0020s1 4860.0036 4860.0037 4860.0038 4860.0053 4860.0014 4860.0092 4860.0094 4860.0225 4860.0426 4860.0003 4860.0150

PreLoad Adjuster Screw Cap 51x1.5 Spacer 42x26.5x2.5 Spacer 42x26.5x5 Spacer 42x26.5x10 Spacer 42x26.5x1.5 Adjustment Tube Adjustment Tube Adjustment Tube Adjustment Tube Adjustment Tube 05 Needle Rebound Needle Rebound

2 2 2 4 4 4 2 2 2 2 2 2 2

$116.99 $47.99 $6.99 $6.99 $6.99 $6.99 $13.99 $41.99 $14.99

$165.58 $78.66 $11.87 $11.87 $11.87 $11.87 $23.18 $23.18 $23.18 $23.18 $11.99 $24.22 $6.99 $10.83 $22.99 $42.01

SX MX/EX S S Was 4860.0039 512 517 492 482 462 S 01 S 02 S S

S S S 03-5 S 03-5 S S 01 S 02-5 S 03/4 S 05 S 01 S 02 S S Adv S S

Dia No 33 34 35 24 24 24 24 24 31 31 31 31 31 31 31 31 38 38 38 38 38 38 38 38 38 38 38 38

Part No

Description

Qty

4860.0189 4860.0046 4860.0033 4860.0011s 4860.0155s 4860.0241s 4860.0342s 4860.0380s 4860.0023 4860.0093 4860.0251 4860.0253 4860.0254 4860.0315 4860.0412 4860.0425 9141.0006s 9141.0008 9141.0011s 9141.0012s 9141.0013s 9141.0014s 9141.0015s 9141.0016s 9141.0017s 9141.0019s 9141.0020s 9141.0040s

Needle Rebound O-Ring 3x1.5 Spring Rebound Needle Hydr Stop D=32.4 Hydr Stop D=31.8 Hydr Stop D=31.9 CPL05 Hydr Stop D=31.9 CPL05 Hydr Stop D=31.9 CPL05 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Piston Rod D=14 m11x1 Spring Spring Spring Spring Spring Spring Spring Spring Spring Spring Spring Spring

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Cost Cost Wire Rate Length 400-520 450/525 640 Nov 09 Nov09 Dia SX SX/EX Adv US Aus mm n/mm 2002 2003-4 2001-5 $30.99 $42.63 S S 03-5 $1.99 $3.75 S S $12.99 $20.52 4 S S S 02 $95.44 200 S 01 $44.99 $81.51 200 S S 03-4 $67.99 $80.17 235 200 S 05 $62.99 $90.52 546 S 01 $90.52 526 S 02 $101.99 $88.08 551 S $88.08 516 526 S 03-4 $95.99 $125.25 526 526 S 05 $80.99 $125.25 496 5.1 4.4 S 02-4 $145.99 $212.91 5.25 4.8 S 01 $145.99 $212.91 3.6 X X $145.99 $212.91 3.8 X X $145.99 $212.91 5 4 X X $145.99 $212.91 4.2 X X $145.99 $212.91 5.1 4.4 S X $145.99 $212.91 4.6 X S $145.99 $212.91 4.8 X X 5.1 4.6 S 05 $145.99 $212.91 5.25 4.8 $145.99 $212.91 5.25 4.8

950 990 Adv/S A, E, S 2003-5 2007 S S S

Adv S Adv

S 04 S 03 S 05

S 04 S 05

S-07

Dia No 38 36 39 42 42 42 43 43 44 44 44 44 45 45 45 47 47 49 49 49 52 52 51 50 50 50 55 12

Part No

Description

Qty

9141.0045s 4860.0113 4860.0021 4357.0132s 4860.0196s 4860.0383s 4681.0651 4860.0239 4860.0015 4860.0192 4860.0261 4860.0403 4860.0025 4860.0151 4860.0203 4860.0059 3548.0377 4860.0062

4860.0042 4860.0201 4860.0060 4860.0212 4054.0486 4860.0001

Spring Washer 32x42x2.5 Interm Ring 26,2x43x3 Screw Sleeve m29,3x1 Screw Sleeve m29,3x1 Screw Sleeve m29,3x1 DU Bush 14x16x12 O-Ring 8x1.25 Rebound Spring D=14.6 Rebound Spring D=15x11 Rebound Spring 34.5x15x11 Rebound Spring 34.5x15x11 Tap Rebound Tap Rebound Tap Rebound D=3 Spring Check Valve D=0.25 Spring Check Valve D=0,5 Check Valve 8x24x0.1 Shims as required Check Valves as required Piston Rebound D=27.7 Piston Rebound B=11.2 Piston Ring 5x1x84 Shims as required Pressure Ring 20x16.25x0.20 Shims as required Nut Rebound m6x0.5 Outer Tube D=54/60

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 8

Cost Nov 09 US $145.99 $10.99 $14.99 $47.99 $107.99 $6.99 $2.99 $18.99 $18.99 $44.99 $36.99 $26.99 $25.99 $36.99 $7.99 $2.99 $3.99

2 2 2

$48.99 $61.99 $4.99 $31.99

2 2

$4.99 $487.99

Cost Wire Rate Length 400-520 450/525 640 Nov09 Dia SX SX/EX Adv Aus mm n/mm 2002 2003-4 2001-5 $212.91 5.5 5.9 $14.25 S S 03-5 $27.00 S S $90.52 39 S 01/2 $113.74 90 S S 03-4 90 S 05 $9.11 S 01 $3.50 ??? S S 03-5 $29.06 22 S 01/2 $22.23 34.5 S S 03-4 $62.71 34.5 $40.34 34.5 S 05 $43.33 S 01 S 01 $40.91 S 02 S 02 $48.53 S S 03-5 $17.28 S 01 $4.14 S S 02-5 $5.32 X S See Shim List Below X X See Shim List Below X S 03-5 $71.81 S S $83.56 $9.09 S S See Shim List Below X X $36.78 See Shim List Below X X $4.69 S S $575.92 577 S 01/2

950 990 Adv/S A, E, S 2003-5 2007 S-06 S S S

S

S 03/4 S 05

S S S

S S X X S

Dia No 12 12 12 12 13 20 20 14 15 15 16 17 17 17 17 17 17 18 19 19 19 19 19 22 22 23 23 23

Part No

Description

Qty

4860.0244 4860.0268 4860.0336 4860.0422 4860.0016 4860.0036 4860.0236 4860.0245 4860.0007 4860.0205 4860.0013 4860.0057 4860.0185 4860.0344 4860.0347 4860.0399 4860.0437 4860.0070 4860.0040 4860.0159 4860.0186 4860.0345 4860.04 4860.0008 4860.0204 4860.0002 4860.0240 4860.0417

Outer Tube D=54/60 Outer Tube D=54/60 Outer Tube D=54/60 Outer Tube D=54/60 05 Guiding Ring D=58mm Guiding Ring 48x51x12 Guiding Ring 48x51x12 Spacer 50.95x0.85x161.5 DU-Bush 48x52x12 DU-Bush 48x52x12 Support Ring 50x57.6x1.5 Oil Seal Ring 48x57.7x9.5 Oil Seal Ring 48x57.6x9.5 Oil Seal Ring 48x57.8x9.5 Oil Seal Ring 48x57.8x9.5 Oil Seal Ring 48x57.8x9.5 Oil Seal Ring 48x57.8x9.5 Lock Washer SB58 Dust Stripper D=48 Dust Stripper D=48 Dust Stripper D=48 Dust Stripper D=48 Dust Stripr D=48 58.4x11.8 DU-Bush 47x49x20 DU-Bush 47x49x20 Inner Tube D=48mm Inner Tube D=48mm Inner Tube D=48mm

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Cost Cost Wire Rate Length 400-520 450/525 640 Nov 09 Nov09 Dia SX SX/EX Adv US Aus mm n/mm 2002 2003-4 2001-5 $529.99 $607.60 577 S S 03 577 S 04-5 $867.99 $775.40 610 $386.99 $712.01 610 $5.99 $4.17 S S $6.99 $11.87 S S 03-4 $25.99 $44.67 S S 03-4 $58.99 $46.74 S 01/2 $17.99 $58.59 S S 03-5 $4.99 $7.78 S S $35.62 S 01/2 $35.62 S 03 $23.99 $50.78 S S 04-5 $26.99 $38.47 ??? $2.99 $5.47 S S Now 4860 00400 S 01 S 02 Now 4860 00400 S 03-4 $46.83 Now 4860 0348 S S 05 $28.86 $34.99 $46.74 Now 4860 0428 S 01/2 $34.99 $46.74 Now 4860 0428 S S 03-5 $415.99 $492.36 590 S 01/2 $244.99 $614.59 595 S S 03-4 $251.99 $375.03 595 S 05

950 990 Adv/S A, E, S 2003-5 2007

S 03/4 S -5 S S S S S

S 05 S 03/4 S

S 03/4 S 05 S S 03/4 S 05

Dia No 23 58 58 58 59 60 60 60 60 60 61 61 61 61 61 62 63 63 64 64 70 71 72 50 69 69 69 82

Part No

Description

Qty

4860.0437 4860.0226 4860.0140 4860.0081 4860.0048 4357.0159 4860.0184 4860.0207s 4860.0237s 4860.0435s 4357.0158 4860.0005 4860.0208s 4860.0238s 4860.0436s 0015.080303 4054.1241 4860.0163 4054.1278 4860.0202 4860.0061 4860.0047 4861.1499 4860.0027s 4860.0152s 4860.0152s1 4860.0141

Inner Tube D=48mm Tube 28x29.3x1 ALU Tube 28x29.3x1 ALU Tube 29.3x1 D=8.5mm O-Ring 46x2 Axle Clamp L/S Rallye 2000 Axle Clamp L/S Adv 02 Axle Clamp L/S D=30 Axle Clamp L/S '04 Axle Clamp L/S '05 Axle Clamp R/S Rallye 2000 Axle Clamp R/S Adv 02 Axle Clamp R/S D=34 Axle Clamp R/S '04 Axle Clamp R/S '05 HH Collar Screw 8x30 Check Valve Nut 6x0.5 Check Valve Nut 6x0.5 D=2 Spring Check Valve D=0.5 Spring Check Valve D=0.7 Check Valve 8x24x0.4 Piston Compression D=27.9 O-Ring 21x2 Shims as required Tap Compression Tap Compression D=35mm Tap Compression D=35mm Rubber Cap

2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4 2 2 2 2 2 2 2

Cost Nov 09 US $246.99 $109.99 $85.99 $91.99 $1.99 $194.99 $272.99 $325.99 $188.99 $161.99 $188.99 $293.99 $188.99 $7.99 $13.99 $3.99 $2.99 $3.99 $48.99 $1.99 $45.99 $62.99 $62.99 $2.99

2 2 2

Cost Wire Rate Length 400-520 450/525 640 Nov09 Dia SX SX/EX Adv Aus mm n/mm 2002 2003-4 2001-5 $379.96 595 $115.33 420 $158.54 385 S 02-5 $115.33 390 S S 01 $3.75 S S $397.17 S 01 S 02/3 $322.30 S 04 $340.04 S $322.30 S 05 $313.39 S 01 S 02/3 $322.30 S 04 $340.04 S $322.30 S 05 $4.06 S S $10.35 S 01/2 $16.15 S S 03-5 $6.74 S 01/2 $3.75 S S 03-5 $5.32 S S $71.81 S S $3.75 S S X $79.33 S 01 $81.88 S S 02 $81.88 S 03-5 $4.36 S S 02-5

950 990 Adv/S A, E, S 2003-5 2007 Adv S Adv S

S S 05

S 03/4 S 05 S S S S S S S

S S

Dia No 99

Part No

Description

Qty

R140.07

Repair Kit 4360 MXMA

1

Cost Cost Wire Rate Length 400-520 450/525 640 Nov 09 Nov09 Dia SX SX/EX Adv US Aus mm n/mm 2002 2003-4 2001-5 $284.99 $319.16 S ?

950 990 Adv/S A, E, S 2003-5 2007 S

81 73 74 74 75 75 75 80 5 6 76 79

Parts Breakdown for item 69 Above 4860.0004 Copper Washer 29.5x33.5x1 3548.0320 O-Ring 24x2 4860.0027 Tap Compression 4860.0152 Tap Compression 4860.0035 Needle Compression m10x1 4860.0153 Needle Compression m10x1 4860.0190 Needle Compression m10x1 4860.0034 Compression Adj Screw 4054.0603 Steel Ball D=3mm 4860.0028 Spring D=2.9 L=7.9 4860.0049 O-Ring 8x2 4860.0051 Lock Washer RB12

2 2 2 2 2 2 2 2 2 2 2 2

$1.99 $2.99 $33.99 $34.99 $5.99 $5.99 $11.99 $7.99 $0.99 $2.99 $3.99 $1.99

$2.84 $5.28 $67.31 $67.31 $8.35 $9.32 $15.46 $13.48 $1.93 $3.69 $11.71 $2.19

S S Now 4860.0586 Now 4860.0586 S S S S S S S

S S S

S S S S S S

S S S 01 S 02-05 S 01 S 02 S 03-05 S S S S S

S S S

S S

S S S S S S

S S S S S

KTM Front Disc & Brake Pad Information MetalGear Part No's Model Year Disc LHS Disc RHS N/A N/A N/A N/A Pad LHS 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.048 30.362 30.183 30.052 30.052 Pad RHS N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Disc Type Solid Solid Solid Solid Solid Floating Solid Solid Solid Solid Disc Information PAD Size OD ID BHC No of BH TH minTH Offset Lengt Width Depth h mm mm mm BH mm mm mm mm mm mm mm 260 260 260 260 300 320 260 260 260 260 126 126 126 126 127 126 126 126 126 127 127 127 143 143 143 143 143 143 143 143 143 143 143 143 6 6 6 6 6 6 6 6 6 6 6 6 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 3.5 3 3.5 3 4 3.5 3.5 3 3 4 5 4 3 2.5 3 2.5 3.5 3 3 2.5 2.5 3.5 4.5 3.5 0 0 0 0 0 0 0 0 0 0 0 0 108.9 41.3 35 40.53 108.9 41.3 94 94 94 94 94 94 94 94 94 94 37.3 37.3 37.3 37.3 37.3 37.3 37.3 37.3 37.3 37.3 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 0 7.6 7.4 8

400 EXC 450 EX/SX 520 EX/SX 525 EX/SX 620SC 620SC-SM 625SC 625 SXC 625 SXC 625 SXC 640LC4Adv 640LC4Adv 640LC4Adv

2000-3 20.031W 2004-6 20.0377W 2000-1 20.031W 2004-5 20.0377W 1996-02 20.357 2000-2 21.063 2002 20.031 2003 20.031 2004 20.0377W 2005-6 20.0377W 98-2000 2001-2 2003-7 20.357 21.063 20.384 20.357 21.063 20.384 21.086

N/A N/A N/A N/A N/A N/A N/A 20.385 N/A N/A 20.385 21.086

N/A Solid 300 N/A Floating 320 30.048 Solid 300 N/A N/A Solid 300 Floating 320

690 Enduro & R 2008-9 690 SMR/SMC 2007-9 950 Adv & S 990 Adv 2003-5 2006-9

30.052 Solid 300 30.052 Floating 300

127

143

6

6.5

5

4.5

0

BMW F650

2000-7

20.223

N/A

30.362

N/A

Solid

300

105

120

6

6.5

5

4.5

0

108.9

41.3

7.6

Dia

Part No

KTM Front Disc Caliper & Wheel Information from online Fiche & Parts Diagrams Description Price Price

No

US

Aus

4357 20mm Axle & Hub Information Listed in assembly order R to L 30 8 6 4 2 2 4 6 8 32 503.09.081.200 503.09.012.000 0760.263770 625.069047 503.09.010.044 503.09.010.144 625.069047 0760.263770 503.09.012.000 503.09.082.100 Axle Front USD43 2001 185mm Spacer Bushing 2000 20x26x27.8 Shaft Seal Ring 26x37x7 ASL Groove Ball Bearing 6904 2RSRC3 Front Hub CPL SX 00 Front Hub CPL SX 00 Groove Ball Bearing 6904 2RSRC3 Shaft Seal Ring 26x37x7 ASL Spacer Bushing 2000 20x26x27.8 Axle Nut Front m16X1.5 ws=27 $80.26 $12.72 $7.68 $25.30 $371.30 $214.99 $399.51 $19.99 $25.30 $2.99 $7.68 $4.99 $12.72 $8.99 $19.48 $42.99 $4.99 $2.99 $19.99 125-525 SX & LC4 2001-2 + 625 SX to 2005 125-525 SX & LC4 2001-2 + 625 SX to 2005

125-525 SX 2001-2 + 625 SX to 2005 No speedo pickup 125-525 EX/MX + LC4 2001-2 Speedo Pickup

125-525 SX & LC4 2001-2 + 625 SX to 2005 125-525 SX & LC4 2001-2 + 625 SX to 2005

15 0015.080353 Collar Screw Caliper 8x35 1 584.13.015.144 Brake Caliper Front LS CPL 300 1 584.13.015.244 Brake Caliper Front LS CPL 320

$2.99 $3.27 All models 2001 to 2010 0015.080350 is an alternative with lock $163.99 $472.90 2001-5 LC4 28mm Piston Includes Support Bracket $239.99 $475.50 2001-2 LC4 28mm Piston Includes Support Bracket

4357 & 4860 30mm Axle & Hub Information Listed in assembly order R to L 18 600.13.049.000 Brake Caliper Support Front RS 1 600.13.016.000 Brake Caliper Fr CPL RS 03 30/32 20 8 2 7 21 600.09.081.000 600.09.013.000 600.09.010.044 600.09.012.000 600.09.082.000 Wheel Spindle Front 2003 Spacer Bushing RS 2003 Front Hub CPL 03 (Dual Disc) Spacer Bushing LS 2003 Collar Screw Front Axle 03 $99.99 $163.17 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.049.000 $224.99 $538.10 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.016.000 $62.99 $13.99 $270.99 $15.99 $11.99 $113.90 $25.47 $451.66 $27.75 $66.21 640 & 950/990 2003 to 2008 640 & 950/990 2003 to 2008 640 & 950/990 2003 to 2008 640 & 950/990 2003 to 2008 640 & 950/990 2003 to 2008

24 590.09.062.013 Disc Rotor Collar Screw 6x13 10.9 21 0015.080353 Collar Screw Caliper 8x35 19 600.13.049.100 Brake Caliper Support Front LS 2 600.13.015.000 Brake Caliper Fr CPL LS 03 30/32

$0.99 $2.49 All models 2001 to 2010 $2.99 $3.27 All models 2001 to 2010 0015.080350 is an alternative with lock $99.99 $155.35 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.049.100 $303.99 $538.10 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.015.100

BMW F650GS

Disc Fixed 300mm

Caliper 2 piston floating 30/32

Brembo 22.5553 Hanger 22.5554

Notes

58413014000 2005 SX Super Moto 320mm Disk support 601.13.049.100 Caliper Hanger is Brembo Part No 18 2240.05 DDU2CG23S6NM

Mfr

Fork Springs WP4357 Part No

Usage

Price $US

Price $A

OD Length

Rate n/mm 5.39 0.53 3.6 3.8 4 4.2 4.4 4.4 5 4.9-5.5

Spring Calcs Dia Weight Coils Preload Comp mm Length 3 2 4.6 4.75 4.75 4.9 4.9 4.9 5 5 4.75 4.75 4.75 3 7 9 14

KTM KTM KTM KTM KTM KTM KTM KTM KTM IKON KTM KTM WJC Teknik Teknik Teknik Teknik YSS BMW TT 19-130-36to52 19-130-66 19-135-46 19-135-50 1622-216 Spec 9501.0010s 9501.0001s 9501.0002s 9501.0003s 9501.0004s 9501.0012s 9501.0022s 500-150

Rebound Rebound WP43 WP43 WP43 WP43 WP43 WP43 WP43

21 19

22.5 34.5

38

510

36.5 34.6 37.1 35.5

173

38.5 KTMEXC-01WJC KTMEXC-01WJC WJC Play Calc SX/MX/EX 01-02 SX/MX/EX 01-02 Kawa KLX 250/300 Kawa KLX 250/300 $189.00 $189.00 38 38 38 38 38

490 508 485 415 510 510 462 462

40 35 33 33

200 166 157 157

0.36 to 0.52 0.66 0.46 0.5

$189.00 38.6 $189.00 38.6 $179.00

467.9

6.2

5

BMW

Tested

34

477

5

46.5

20

232.5

Fork Springs WP4860 Mfr Part No Usage Price $US Price $A OD Length Rate n/mm 0.36 to 0.52 0.66 0.38 to 0.50 0.58 0.6 0.36 to 0.54 0.48 3.6 3.8 4 4.2 4.4 4.6 4.8 4.8 4.8 5.9 Dia mm

Spring Calcs Coils Preload Comp Length

Teknik Teknik Teknik Teknik Teknik Teknik Eibach KTM KTM KTM KTM KTM KTM KTM KTM KTM KTM

19-165-36to52 19-165-66 19-180-38to50 19-180-58 19-180-60 19-190-36to54 974.048.1 9141.0011s 9141.0012s 9141.0013s 9141.0014s 9141.0015s 9141.0016s 9141.0017s 9141.0020s 9141.0040s 9141.0045s

SX 2007 SX 2007 04-06 640/950, 08 SX 04-06 640/950, 08 SX 04-06 640/950, 08 SX 02-04 SX, 03-09 EX

$189.00 43.5 $189.00 43.5 $189.00 $189.00 $189.00 $189.00 43 43 43 43 43.2

461 461 485 485 485 505 508

WP48 WP48 WP48 WP48 WP48 WP48 WP48 WP48 WP48 WP48

5 5.1

5.25 5.25 5.5

Travel mm 14 21

337

290 342 328 258

224.5

Travel mm

Weight F650GS Fork Component Weight Information Component BMW BMW (MaxBMW) Weighed KTM4357 KTM4860

Summary Handle Bar Mount Complete Upper Yoke & Bolts Lower Yoke, Post & Bolts LHS Fork Leg Complete RHS Fork Leg Complete Fork Brace, Bolts & B Brkt Left Fork Guard & Bolts Right Fork Guard & Bolts Axle, Axle Nut & Spacers Front Wheel 300mm Disk Caliper & Hanger Totals Weight Savings Forks, Brace & Axle Component Detail Handlebar Mount Bolts 4 Handlebar Mount Caps 2 Handlebar Mount Bolts 2 Handlebar Mount KTM only Handlebar Risers 2 Ignition Switch Mount & Bolts Yoke Collar Nut / Cap Counter Pipe BMW only Upper Yoke Upper Yoke Bolts 2 / 5 Adjusting Ring Ring (BMW) / Seal (KTM) Upper Yoke Total Weight Ring (BMW) / Seal (KTM) Lower Yoke & Post Lower Yoke Pinch Bolts 4 0.086 0.080 NA NA NA 0.040 0.050 0.830 0.040 0.150 0.086 0.080 NA NA 0.110 0.040 0.050 0.830 0.032 0.150 0.086 0.058 0.040 0.102 0.110 0.025 NA 0.618 0.080 NA NA 1.28 2.33 4.76 4.65 0.20 NA NA 0.37 3.46 1.73 0.98 19.74 13.58 0.16 1.11 2.40 4.76 4.65 0.39 NA NA 0.37 3.46 1.73 0.98 20.00 13.84 0.34 0.70 1.20 4.23 4.03 NA 0.15 0.16 0.33 3.41 1.54 1.11 17.20 2.80 11.14 0.00 19.74 0.00

1.276

1.378

1.119

0.000

2.330 0.080 Page 39

2.330 0.064

1.103 0.064

Weight Horn Mount, Bolt & Spacers Lower Yoke Weight Fork Cap / Adjuster Adjustment Tube Preload Spacers Spring Hydra Stop Damper Rod / Damper CPL Staunchion / Upper Leg Upper DU Bush Fork Seals & Rings Upper Complete 3.210 Fork Brace Fork Brace Spacers Fork Brace Bolts Brake Line Bracket 2 x Lower DU Bushes Lower Fork Leg - LHS Lower Fork Leg - RHS Axle Clamp & Bolts LHS Axle Clamp & Bolts RHS 2 x Compression Valves 0.060 2.470 0.132 NA 0.010 0.662 NA 0.310 2.020 0.055 6.378 0.200 0.040 0.090 0.020 0.060 0.960 0.960 NA NA NA 2.330 Total Fork Weight Axle RHS Wheel Spacer Front Wheel Caliper Hanger & Bolts Disc Caliper LHS Disc LHS Wheel Spacer Axle Nut Front Wheel Total Weight Total Front End Weight 12.454 0.060 2.454 0.133 NA 0.080 0.662 NA 0.310 2.025 0.055 6.530 0.206 0.030 0.093 0.060 1.045 0.950 NA 0.015 NA 2.399 12.761 0.060 1.227 0.115 0.022 0.016 0.518 0.093 0.492 1.280 0.042 0.046 5.248 NA NA NA 0.038 1.055 1.064 0.460 0.300 0.146 3.063 10.657 0.286 0.010 3.410 0.235 0.875 1.540 0.010 0.016 6.382 17.039 0.000 0.000 0.000 0.000 0.000 0.000

0.327 0.322 0.020 0.040 3.460 3.460 Inc Caliper Inc Caliper 0.975 0.975 1.725 1.725 0.090 0.090 NA NA 6.597 19.051 6.612 19.373

Page 40

Weight

Yamaha

11.40

0.33 3.41

15.15 4.85 11.73

0.000

Page 41

Weight

0.000

0.000

0.000 0.000

1.11

0.000 0.000

Page 42

Dia No

Part No

Description

Thick ness

Standard 640 Adv 2002 2003 2005 154 24 178 4.4 5 158 158

640Adv Mod 02 03 154 91 24 269 5 5 5 100 158 86 24 268 5 5 100

F650 F650 You1 You2 168 165 65 65 15.75 15.75 249 246 4.6 4.6 5 5 5 5 Mid X Mid X

Shims Reqd Shims Available You1 You2 EXC Buy Spare Notes Shim lists below are for 2 fork legs Bold text indicates calculated cells

exc300 As Rx 108 65 5 178 0.38 5 5 Mid X

Dry Machine Weight (kgs) Kitted Rider Weight (kgs) Fuel & Oil/Water Weight (0.75xL)+3kgs Total Weight Springs Fitted (n/mm or kg/mm) Preload (mm) Oil Viscosity Air Gap (mm) Rebound/Comp Clickers 45 4860.0025 Rebound Tap (+ Spring) 45 4860.0151 Rebound Tap (+ Spring) 45 4860.0203 Rebound Tap (+ Spring) Mid Valve Available Length Stack (mm) Float (mm) Shim 8x10 0.2 Shim 8x20 0.15 Shim 8x20 0.1 Shim 8x14 0.1 Check Valve 8x12 0.1 Shim 8x10 0.1 Shim 8x14 0.1 Check Valve 8x18 0.1 Check Valve 8x20 0.1 Check Valve 8x22 0.1 Check Valve 8x24 0.1 Check Valve 8x24 0.15 Shim 6x8.0 0.1 Shim 6x8.0 0.3

24 22.75 182 181 4.4 4.6 4 5 5 120

X X ? 0.40 1.20 ? 0.70 1.80 X ? 0.70 2.50

X X ? ? 0.95 ##### 1.05 1.13 1 2 1 1 1 1 1 1 1 3 ? ? 1 1 1 1 1 1 1 3 0 2 2.15 1.00 1.15 2.15 1.15 1.00 4 2 2 2 2 2 2 2 8 2 2 1 2 ##### ##### ##### ##### ##### ##### ##### ##### ##### ##### 2 ##### ##### 1.95 0.40 1.55

4860.0480

1 1 1 2 1 1 1 3 0 2 2 2 2 2 2 2 2 6

2 2 2 4 2 2 2 6

4860.0213 4860.0351 4860.0213 4860.0068 4860.0215 4860.0216 4860.0062

49 49 49 49

4 1 1

1 1 1 4 ? ?

1 1 1 4 ? ?

1 1 1 1 1 1 1 ? ?

4 1 1

49 4054.1414 49 4054.1408

4

4

Dia Part No Description Thick No ness Rebound Valve 45 4860.0025 Rebound Tap Fitted 45 4860.0151 Rebound Tap Fitted 45 4860.0203 Rebound Tap Fitted Valve Shaft Length Nut Spring Base Recess Depth 10 mm Valve Section Length 8 mm Valve Section Length 6 mm Valve Section Length Valve Piston 8mm Instep (on top side) Valve Piston Thickness Rebound Nut Length Max Rebound Valve Length 52 4860.0042 Rebound Piston Length Available Stack Size Free Length 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.15 0.1 0.1 0.3 0.25

Standard 640 Adv 2002 2003 2005

640Adv Mod 02 03

F650 F650 You1 You2 X X

Shims Reqd Shims Available You1 You2 EXC Buy Spare

exc300 As Rx

X X X

X X 27 2.05 3.9 3.6 19.5 2.05 12 6.7 2.85 27 2.05 3.9 3.6 19.5 2.05 12 6.7 2.85 X 2.25 1.4 0.85 2 2 1 1 1 1 X X 27 2.05 3.9 3.6 19.5 2.05 12 6.7 2.85 X 2.45 1.4

X 1.45

X 1.45

X 1.55

X 1.4 ? 1.4

X 1.4

X 2.25 1.3 0.95 2 1 1 1 1 1

50 50 50 50 50 50 50 50 50 50 50 50 55

4860.0116 Shim 6x24 Delta 4054.0401 Shim 6x14 4860.0139 Shim 6x22 Delta 4860.0065 Shim 6x20 4054.0403 Shim 6x18 4054.0402 Shim 6x16 4054.0401 Shim 6x14 4054.0405 Shim 6x14 4054.1383 Shim 6x11 4054.0401 Shim 6x14 4054.0447 Shim 6x10 4054.0414 Shim 6x16 4054.0486 Rebound Nut 6x0.5

5

5

5

4

4

4 2 2 2 2 2

4 4 2 2 2 2

1 1 1 1

1 1 1 1

1 1

1 1 1 1

1 1 1 1

4 2 2 2 2 2 2

2

2 1 1 1 1 1 1

##### 2 1 1 1 X ##### ##### 1 1 X 1 1 X 1 1 X 1 1 X 2 2 X 2 2 X 2 2 X 1 1 X

1 1 X

1 1 X

Dia Part No Description Thick No ness Compression Valve 63 4860.0163 Tap Nut + Spring Height Tap Nut 8mm Shaft Length Check Valve float 70 4860.0061 Check Valve 8x24 0.4 Valve Shaft Length Comp Piston 8mm Instep 4860.0047 Comp Piston / Height Shim Stack Length Available Stack Size 4860.0063 Shim 6x24 0.1 4054.0400 Shim 6x12 0.1 4054.0404 Shim 6x12 0.15 4860.0063 Shim 6x24 0.1 4860.0064 Shim 6x22 0.1 4860.0065 Shim 6x20 0.1 4054.0403 Shim 6x18 0.1 4054.0402 Shim 6x16 0.1 4054.0406 Shim 6x16 0.15 4054.0410 Shim 6x16 0.2 4054.0401 Shim 6x14 0.1 4054.0405 Shim 6x14 0.15 4054.0409 Shim 6x14 0.2 4054.0400 Shim 6x12 0.1 4054.1402 Shim 6x11 0.2 4054.1391 Shim 6x11 0.3 4054.0447 Shim 6x10 0.3 4054.0426 Shim 6x9 0.2 4054.0411 Shim 6x18 0.2 4054.0415 Shim 6x18 0.25 4860.0027 Compression Tap 4860.0152 Compression Tap

Standard 640 Adv 2002 2003 2005 6.5 3.8 1.55 1 16.5 X X

640Adv Mod 02 03 X X

F650 F650 You1 You2 6.5 3.8 1.55 1 16.5 1.85 8.9 1.6 1.35 2 1 1 1 1 1 1 6.5 3.8 1.55 1 16.5 1.85 8.9 1.65 1.3 2 1 1 1 1 1 1

Shims Reqd Shims Available You1 You2 EXC Buy Spare X X X

exc300 As Rx 6.5 3.8 1.55 1 16.5 1.85 8.9 1.6 1.35 2

1

1

1

1

2

2

71

50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 74 74

1.85 1.85 X X ##### 1.95 1.85 6 6

1.85 X 1.85 5

1.85 X 1.6 2 1 1 1 1 1 1

1.85 X 1.3 2 1 1 1 1 1 1

4 2 2 2 2 2 2

4 2 2 2 2 2 2

4 2 2 2 2 2 2 2 ##### ##### ##### #####

1 1 1 1 1

2 2 2 1

2 2 1

2 1 1

1 1 1 1 1 1 1 1 1 3 2 1 X. 1 X 1 X X X X X X X X 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2

1 ##### ##### ##### ##### ##### 1 ##### ##### ##### 1 X

49 4054.1414 49 4054.1408 49 4054.1416 4054.1417 4054.0425 4054.0418 4054.0426 50 4054.0449 4054.0419 4054.0423 4054.0427 50 4054.045 4054.1404 4054.1405 4054.1403 50 4860.0217 50 4054.0447 50 4054.1383 4860.0323 4054.1406 4860.0324 50 4054.1402 50 4054.0417 50 4054.1391 50 4054.0400 50 4054.0404 4054.0408 4054.0412 4054.1393 50 4860.0325 4860.0326

Shim 6x8.0x0.1 Shim 6x8.0x0.3 Shim 6x8.0x0.3 Shim 6x8.5x0.1 Shim 6x8.5x0.2 Shim 6x9.0x0.1 Shim 6x9.0x0.2 Shim 6x9x0.3 Shim 6x9.5x0.1 Shim 6x9.5x0.15 Shim 6x9.5x0.2 Shim 6x9.5x0.3 Shim 6x10x0.1 Shim 6x10x0.15 Shim 6x10x0.2 Shim 6x10x0.25 Shim 6x10x0.3 Shim 6x11x0.1 Shim 6x11x0.1 Shim 6x11x0.15 Shim 6x11x0.15 Shim 6x11x0.2 Shim 6x11x0.25 Shim 6x11x0.3 Shim 6x12x0.1 Shim 6x12x0.15 Shim 6x12x0.2 Shim 6x12x0.25 Shim 6x12x0.3 Shim 6x13x0.1 Shim 6x13x0.15

$1.99 $1.99 $1.99 $1.99 $2.99 $9.99 $2.99 $2.99 $2.99 $16.99 $2.99 $1.99 $2.99 $2.99 $2.99 $3.99 $1.99 $2.99 $7.99 $3.99 $7.99 $2.99 $2.99 $2.99 $2.99 $3.99 $3.99 $3.99

$3.75 $3.75 $3.75 $4.56 $6.56 $17.19 $6.56 $3.75 $6.56 $26.55 $6.56 $3.42

$4.17 $3.75 $4.56 $8.83 $29.69 $8.83 $4.56 $6.56 $4.56 $4.56 $5.32 $4.69 $4.56 $4.56 $7.99 $8.83 $7.99 $8.83

50 4054.0401 50 4054.0405 4054.0409 4054.0413 50 4860.0327 4860.0328 50 4054.0402 50 4054.0406 4054.0410 50 4054.0414 50 4860.0329 4860.0330 50 4054.0403 50 4054.0407 50 4054.0411 50 4054.0415 4054.0494 50 4860.0331 50 4860.0065 4860.0069 4860.0095 4860.0096 4860.0332 50 4860.0064 4860.0097 4860.0098 4860.0099 4860.0333 50 4860.0063 4860.0100 4860.0101 4860.0102

Shim 6x14x0.1 Shim 6x14x0.15 Shim 6x14x0.2 Shim 6x14x0.25 Shim 6x15x0.1 Shim 6x15x0.15 Shim 6x16x0.1 Shim 6x16x0.15 Shim 6x16x0.2 Shim 6x16x0.25 Shim 6x17x0.1 Shim 6x17x0.15 Shim 6x18x0.1 Shim 6x18x0.15 Shim 6x18x0.2 Shim 6x18x0.25 Shim 6x18x0.4 Shim 6x19x0.1 Shim 6x20x0.1 Shim 6x20x0.15 Shim 6x20x0.2 Shim 6x20x0.25 Shim 6x21x0.1 Shim 6x22x0.1 Shim 6x22x0.15 Shim 6x22x0.2 Shim 6x22x0.25 Shim 6x23x0.1 Shim 6x24x0.1 Shim 6x24x0.15 Shim 6x24x0.2 Shim 6x24x0.25

$2.99 $2.99 $2.99 $2.99 $7.99 $2.99 $2.99 $3.99 $2.99 $7.99 $7.99 $2.99 $4.99 $2.99 $2.99 $4.99 $4.99 $2.99 $3.99 $3.99 $3.99 $7.99 $2.99 $3.99 $3.99 $3.99 $7.99 $2.99 $3.99 $3.99 $3.99

$4.56 $4.56 $4.56 $4.56 $8.83 $29.69 $4.56 $4.56 $4.15 $4.56 $8.83 $8.03 $4.56 $4.69 $4.56 $4.56 $6.45 $8.83 $4.56 $4.69 $4.56 $4.56 $8.83 $4.56 $4.56 $4.56 $4.56 $8.83 $4.56 $4.15 $4.56 $4.56

4054.0774 Shim 6x18x0.1 Delta 50 4860.0139 Shim 6x22x0.1 Delta 50 4860.0116 Shim 6x24x0.1 Delta

$3.99 $5.32 $3.99 $5.32 $3.99 $5.32

4054.0774 Shim Triangular 6 x18 4054.0775 Shim Triangular 6 x18 4054.0776 Shim Triangular 6 x18

$3.99 $5.32 $3.99 $5.32 $3.99 $5.32

49 49

49 49

4860.0480 4860.0357 4860.0346 4860.0352 4860.0351 4860.0213 4860.0385 4860.0214 4860.0350

Shim 8x10x0.20 CheckValve 8x11x0.1 Shim 8x11x0.2 CheckValve 8x11x0.2 CheckValve 8x12x0.1 Shim 8x14x0.10 Shim 8x14x0.25 Shim 8x16x0.1 CheckValve 8x16x0.15

2.99 4.55 5.99 5.32 7.99 8.34 $4.99 $5.32 $4.99 $5.32 2.99 $5.88 $5.69 $5.99 $5.88 $4.99 $8.34

49 49 49 49

4860.0555 4860.0068 4357.0120 4054.0477 4860.0215 4860.0216 4860.0384 4860.0062 4860.0061

Shim 8x16x0.20 CheckValve 8x18x0.1 Shim 8x18x0.1 Shim 8x18x0.4 CheckValve 8x20x0.1 CheckValve 8x22x0.1 CheckValve 8x22x0.3 CheckValve 8x24x0.1 CheckValve 8x24x0.4

19.99 3.99 $8.99 3.99 $5.99 $5.99 $5.99 $3.99 3.99

$55.74 $5.32 $10.76 $6.45 $5.32 $5.69 $5.69 $5.32

Shims Sorted by Part No 50 50 50 50 50 50 50 50 4054.0400 4054.0401 4054.0402 4054.0403 4054.0404 4054.0405 4054.0406 4054.0407 4054.0408 4054.0409 4054.0410 4054.0411 4054.0412 4054.0413 4054.0414 4054.0415 4054.0417 4054.0418 4054.0419 4054.0423 4054.0425 4054.0426 4054.0427 4054.0447 4054.0449 4054.045 4054.0494 4054.1383 4054.1391 4054.1393 4054.1402 Shim 6x12x0.1 Shim 6x14x0.1 Shim 6x16x0.1 Shim 6x18x0.1 Shim 6x12x0.15 Shim 6x14x0.15 Shim 6x16x0.15 Shim 6x18x0.15 Shim 6x12x0.2 Shim 6x14x0.2 Shim 6x16x0.2 Shim 6x18x0.2 Shim 6x12x0.25 Shim 6x14x0.25 Shim 6x16x0.25 Shim 6x18x0.25 Shim 6x11x0.25 Shim 6x9.0x0.1 Shim 6x9.5x0.1 Shim 6x9.5x0.15 Shim 6x8.5x0.2 Shim 6x9.0x0.2 Shim 6x9.5x0.2 Shim 6x10x0.3 Shim 6x9x0.3 Shim 6x9.5x0.3 Shim 6x18x0.4 Shim 6x11x0.1 Shim 6x11x0.3 Shim 6x12x0.3 Shim 6x11x0.2 $2.99 $2.99 $2.99 $2.99 $3.99 $2.99 $2.99 $4.99 $3.99 $2.99 $3.99 $2.99 $3.99 $2.99 $2.99 $2.99 $2.99 $9.99 $2.99 $16.99 $2.99 $2.99 $2.99 $1.99 $2.99 $1.99 $4.99 $2.99 $2.99 $4.56 $4.56 $4.56 $4.56 $5.32 $4.56 $4.56 $4.69 $4.69 $4.56 $4.15 $4.56 $4.56 $4.56 $4.56 $4.56 $6.56 $7.24 $6.56 $26.55 $6.56 $6.56 4054.1403 4054.1404 4054.1405 4054.1406 4054.1408 4054.1414 4054.1416 4054.1417 4860.0063 4860.0064 4860.0065 4860.0069 4860.0095 4860.0096 4860.0097 4860.0098 4860.0099 4860.0100 4860.0101 4860.0102 4860.0217 4860.0323 4860.0324 4860.0325 4860.0326 4860.0327 4860.0328 4860.0329 4860.0330 4860.0331 4860.0332 4860.0333 Shim 6x10x0.2 Shim 6x10x0.1 Shim 6x10x0.15 Shim 6x11x0.15 Shim 6x8.0x0.3 Shim 6x8.0x0.1 Shim 6x8.0x0.3 Shim 6x8.5x0.1 Shim 6x24x0.1 Shim 6x22x0.1 Shim 6x20x0.1 Shim 6x20x0.15 Shim 6x20x0.2 Shim 6x20x0.25 Shim 6x22x0.15 Shim 6x22x0.2 Shim 6x22x0.25 Shim 6x24x0.15 Shim 6x24x0.2 Shim 6x24x0.25 Shim 6x10x0.25 Shim 6x11x0.1 Shim 6x11x0.15 Shim 6x13x0.1 Shim 6x13x0.15 Shim 6x15x0.1 Shim 6x15x0.15 Shim 6x17x0.1 Shim 6x17x0.15 Shim 6x19x0.1 Shim 6x21x0.1 Shim 6x23x0.1 $2.99 $2.99 $2.99 $3.99 $1.99 $1.99 $1.99 $1.99 $2.99 $2.99 $2.99 $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 $3.99 $7.99 $7.99 $7.99 $7.99 $7.99 $7.99 $7.99 $4.99 $7.99 $7.99

49 49 49 50 50 50

50

50 50 50

50

50 50 50 50 50 50

$3.75 $3.75 $3.42 $6.45 $4.56 $4.56 $4.56 $2.99 $4.56

50 50 50 50

$29.69 $3.75 $3.75 $3.75 $4.56 $4.56 $4.56 $4.56 $4.56 $4.56 $4.56 $4.56 $4.56 $4.56 $4.15 $4.56 $4.56 $4.17 $8.83 $8.83 $8.83 $8.83 $8.83 $29.69 $8.83 $8.03 $8.83 $8.83 $8.83

4054.0477 49 4357.0120 4860.0061 49 4860.0062 4860.0068 4860.0213 49 4860.0214 49 4860.0215 49 4860.0216

Shim 8x18x0.4 Shim 8x18x0.1 CheckValve 8x24x0.4 CheckValve 8x24x0.1 CheckValve 8x18x0.1 Shim 8x14x0.10 Shim 8x16x0.1 CheckValve 8x20x0.1 CheckValve 8x22x0.1

3.99 $8.99 3.99 $3.99 3.99 2.99 $5.99 $5.99 $5.99

$6.45 $10.76 $5.32 $5.32 $5.88 $5.88 $5.32 $5.69

4860.0346 Shim 8x11x0.2 49 4860.0350 CheckValve 8x16x0.15 49 4860.0351 CheckValve 8x12x0.1 49 4860.0352 CheckValve 8x11x0.2 4860.0357 CheckValve 8x11x0.1 4860.0384 CheckValve 8x22x0.3 4860.0385 Shim 8x14x0.25 4860.0480 Shim 8x10x0.20 4860.0555 Shim 8x16x0.20

7.99 $4.99 $4.99 $4.99 5.99 $5.99

8.34 $8.34 $5.32 $5.32 5.32 $5.69 $5.69 2.99 4.55 19.99 $55.74

Husa Dia No Part No Description Qty Husa 450-1 Husa 450-2

Springs Fitted Rebound Valve

45 47 49 49 49 49 52 51 50 50 50 50 50 50 50 50 50 50

4860.0025 Tap Rebound 3548.0377 Spring Check Valve D=0.5 4860.0062 Check Valve 8x24x0.1 4860.0062 Check Valve 8x24x0.1 4860.0062 Check Valve 8x24x0.1 4860.0062 Check Valve 8x24x0.1 4860.0042 4860.0060 4860.0116 4860.0116 4054.0401 4860.0139 4860.0065 4054.0403 4054.0402 4054.0405 4054.0447 4054.0414 Piston Rebound D=27.7 Piston Ring 5x1x84 Shim 6x24x0.1 Delta Shim 6x24x0.1 Delta Shim 6x14x0.1 Shim 6x22x0.1 Delta Shim 6x20x0.1 Shim 6x18x0.1 Shim 6x16x0.1 Shim 6x14x0.15 Shim 6x10x0.3 Shim 6x16x0.25

? ? ? ?

? ? ? ?

24dx0.1 24dx0.1 24dx0.1 16x0.1 24dx0.1 22x0.1 20x0.1 18x0.1 17x0.1 14x0.1 12x0.1 10x0.2 10x0.2

24dx0.1 24dx0.1 24dx0.1 14x0.1 22x0.1 20x0.1 17x0.1 14x0.1 12x0.1 10x0.2 10x0.2

55

4054.0486

Nut Rebound m6x0.5

Compression Valve

63 64 70 71 72 50

4860.0163 Check Valve Nut 6x0.5 D=2 4860.0202 Spring Check Valve D=0.5 4860.0061 Check Valve 8x24x0.4 4860.0047 Piston Compression D=27.9 4861.1499 O-Ring 21x2 4860.0063 Shim 6x24x0.1

1 1 1 1 1 1

?

?

24x0.1

24x0.1

Page 48

Husa 50 50 50 50 50 50 50 50 50 4860.0063 4054.0404 4860.0064 4860.0065 4054.0403 4054.0402 4054.0401 4054.0447 4054.0411 Shim 6x24x0.1 Shim 6x12x0.15 Shim 6x22x0.1 Shim 6x20x0.1 Shim 6x18x0.1 Shim 6x16x0.1 Shim 6x14x0.1 Shim 6x10x0.3 Shim 6x18x0.2 1 1 1 1 1 1 1 1 1 16x0.1 24x0.1 24x0.1 22x0.1 20x0.1 18x0.1 15x0.1 13x0.1 11x0.1 9x0.3 24x0.1 16x0.1 24x0.119x0.1 17x0.1 15x0.1 14x0.1 13x0.1 12x0.1 11x0.1

9x0.3 69 4860.0152s1 Tap Compression D=35mm 2

Page 49

Husa

Page 50

Husa

Page 51

Spring Calcs F650GS Machine Dry Weight Oil & Water L Oil & Water kg Fuel Capacity Fuel Weight Wet Weight 177 2.3&1.3 3.025 17 12.75 192.775 167 2.3&1.3 3.025 17 12.75 182.775 Yourf650 Yamaha KTM YZF426 300EXC 2001 2001 107 1.2&1.2 7 5.25 112.25 102 0.8&1.3 1.9 11 8.25 112.15 KTM 640LC4 2003 149 2.1&1 2.575 11 8.25 159.825 KTM 640Adv 2001-3 158 2.1&2.1 3.675 28 21 182.675

Std Spring Spring Length Wire Dia Preload Air Chamber

6.2 467.9 5

4.6 462

4

4.2

4.4

5 150

6 150

Racetech Spring Recommendations Rider Weight 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 44 55 66 77 88 99 110 121 132 143 154 165 176 187 198 209 220 231 243 254 265 276 287 298 309 320 331 342 353 364 375 386 397 408 F650GS 0.640 0.659 0.677 0.695 0.714 0.732 0.750 0.769 0.787 0.806 0.824 0.843 0.861 0.879 0.898 0.916 0.935 0.953 0.971 0.990 1.008 YZF426 300EXC 640LC4DS 0.386 0.393 0.400 0.406 0.413 0.419 0.426 0.433 0.439 0.446 0.453 0.459 0.466 0.472 0.479 0.486 0.492 0.499 0.505 0.512 0.519 0.525 0.532 0.538 0.545 0.552 0.558 0.565 0.571 640AdvR 0.386 0.393 0.400 0.406 0.413 0.419 0.426 0.433 0.439 0.446 0.453 0.459 0.466 0.472 0.479 0.486 0.492 0.499 0.505 0.512 0.519 0.525 0.532 0.538 0.545 0.552 0.558 0.565 0.571

0.403 0.409 0.416 0.423 0.429 0.436 0.444 0.449 0.456 0.462 0.469 0.476 0.482 0.489 0.495 0.502 0.509 0.515 0.522 0.528 0.535 0.542 0.548 0.555 0.561 0.568 0.575 0.581 0.588 0.594

0.355 0.364 0.373 0.382 0.391 0.400 0.409 0.418 0.427 0.436 0.446 0.455 0.462 0.473 0.482 0.491 0.500 0.509 0.518 0.527 0.536 0.545 0.555 0.564 0.573 0.582 0.591 0.600 0.609 0.618

190 195 200 Notes

419 430 441

0.601 0.608 0.614

0.627 0.636 0.645

KTM dry weight actually dead weight without fuel KTM 640 2001 to 2003 LC4 & Adv all the same weight changes 136 149 to 158 Riding type made no change in rec, fuel tank size did

Total Weight

F650GS 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 342 353 364 375 386 397 408 419 430 441 452 463 474 485 496 507 518 529 540 551 562 573 584 595 606 617 628 639 650 661 672 683 694 705 717 728

0.640 0.659 0.677 0.695 0.714 0.732 0.750 0.769 0.787 0.806 0.824 0.843 0.861 0.879 0.898 0.916 0.935 0.953 0.971 0.990 1.008

YZF426 300EXC 0.403 0.355 0.409 0.364 0.416 0.373 0.423 0.382 0.429 0.391 0.436 0.400 0.444 0.409 0.449 0.418 0.456 0.427 0.462 0.436 0.469 0.446 0.476 0.455 0.482 0.462 0.489 0.473 0.495 0.482 0.502 0.491 0.509 0.500 0.515 0.509 0.522 0.518 0.528 0.527 0.535 0.536 0.542 0.545 0.548 0.555 0.555 0.564 0.561 0.573 0.568 0.582 0.575 0.591 0.581 0.600 0.588 0.609 0.594 0.618 0.601 0.627 0.608 0.636 0.614 0.645

640LC4DS

640AdvR

0.386 0.393 0.400 0.406 0.413 0.419 0.426 0.433 0.439 0.446 0.453 0.459 0.466 0.472 0.479 0.486 0.492 0.499 0.505 0.512 0.519 0.525 0.532 0.538 0.545 0.552 0.558 0.565 0.571

0.386 0.393 0.400 0.406 0.413 0.419 0.426 0.433 0.439 0.446 0.453 0.459 0.466 0.472 0.479 0.486 0.492 0.499 0.505 0.512 0.519 0.525 0.532 0.538 0.545 0.552 0.558 0.565 0.571

Volume Calculations

ID of Tube IR of Tube Area of Tube Length of Tube

Avail 10 5 78.54

15 7.5 176.71

19 avail 20 10 314.1592654

25 12.5 490.874

50 100 105 110 115 120 125 130 135 140 145 150

3.9 7.9 8.2 8.6 9.0 9.4 9.8 10.2 10.6 11.0 11.4 11.8

8.8 17.7 18.6 19.4 20.3 21.2 22.1 23.0 23.9 0.0 25.6 26.5

15.7 31.4 33.0 34.6 36.1 37.7 39.3 40.8 42.4 44.0 45.6 47.1

24.5 49.1 51.5 54.0 56.5 58.9 61.4 63.8 66.3 68.7 71.2 73.6

KTM 950 2003 206 3 & 2.1 4.35 22 16.5 226.85

4.8

950Adv 0.476 0.483 0.490 0.496 0.503 0.509 0.516 0.523 0.529 0.536 0.543 0.549 0.556 0.562 0.569 0.576 0.582 0.589 0.595 0.602 0.609

950Adv

Spring Rate Comparison1.200

WJC Weight 0.476 0.483 0.490 0.496 0.503 0.509 0.516 0.523 0.529 0.536 0.543 0.549 0.556 0.562 0.569 0.576 0.582 0.589 0.595 0.602 0.609 0.622 0.635 0.6481.000 1.1059322

1.100823050.800

Spring Rate

1.098196390.600

0.400

0.200

0.000 342 364 386 408 430 452 474 496 518 540 562 584 606 628 650 672

Total Machine & Rider Weight - lbs

Fork Volume 44 22 1520.53084 49 24.5 1885.74099

76.0 152.1 159.7 167.3 174.9 182.5 190.1 197.7 205.3 212.9 220.5 228.1

94.3 #N/A 198.0 207.4 216.9 226.3 235.7 245.1 254.6 264.0 273.4 282.9

F650GS YZF426300EXC

640LC4DS 640AdvR 950Adv

672

694

Spring Rate Comparison1

0.95

0.9

0.85

0.8

0.75

Spring Rate - kg/mm

0.7

F650GS

YZF426

0.65

300EXC

640LC4DS

0.6

640AdvR

950Adv

0.55

0.5

0.45

0.4

0.35

0.320 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160

Rider Weight - kgs

Spring Rate Comparison

Spring Rate Comparison1.050 1.000 0.950 0.900 0.850 0.800 0.750 0.700 0.650 0.600 0.550 0.500 0.450

Spring Rate - kg/mm

F650GS YZF426300EXC

640LC4DS 640AdvR950Adv

0.400 0.350 0.300155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315

Total Machine & Rider Weight - Kgs

Spring Rate Comparison

1.050

1.0000.950 0.900

0.8500.800 0.750 0.700

Spring Rate - kg/mm

F650GSYZF426

300EXC 640LC4DS640AdvR

0.6500.600 0.550 0.500

950Adv

0.4500.400 0.350 0.300 342 353 364 375 386 397 408 419 430 441 452 463 474 485 496 507 518 529 540 551 562 573 584 595 606 617 628 639 650 661 672 683 694

Total Machine & Rider Weight - lbs

Principal dimensions (mm) Usage ID d 0D Width B

Basic load ratings Dynamic Static kN kN C C0

Fatigue Load Limit Pu

Speed ratings Reference Limiting Speed Speed rpm rpm

Steering Head Bearing Info BMW Fun BMW GS Honda KTM 640 Yamaha ??? 25 28 25 29 28 30 52 52 47 50.292 52 52 16,25 16 15 14.224 16 17 30,8 31,9 27 26 31,9 35,8 33,5 38 32,5 32.5 38 44 3,45 4 3,25 3.35 4 4,55 10000 10000 11000 10000 10000 9000 13000 13000 14000 14000 13000 12000

Wheel Bearing Info 15 15 15 15 15 15 15 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 20 20 20 20 20 20 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 35 35 35 35 35 35 35 35 35 35 37 37 37 42 42 42 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 8 8 10 10 10 10 10 10 10 14 9 9 9 12 12 12 8,06 8,06 8,06 8,06 8,06 8,06 8,06 9,95 11,4 9,95 9,95 9,95 9,95 9,95 9,95 6,37 6,37 6,37 6,37 6,37 6,37 6,37 6,37 6,37 6,05 6,37 6,37 6,37 9,95 9,95 9,95 3,75 3,75 3,75 3,75 3,75 3,75 3,75 4,75 5,4 4,75 4,75 4,75 4,75 4,75 4,75 3,25 3,25 3,25 3,25 3,25 3,25 3,25 3,25 3,25 3,25 3,65 3,65 3,65 5 5 5 160 160 160 160 160 160 160 200 228 200 200 200 200 200 200 137 137 137 137 137 137 137 137 137 137 156 156 156 212 212 212 43000 43000 43000 43000 43000 38000 38000 38000 38000 38000 38000 45000 45000 45000 45000 45000 45000 45000 43000 43000 38000 38000 28000 13000 22000 22000 13000 28000 28000 24000 24000 12000 19000 19000 12000 24000 24000 28000 22000 28000 13000 22000 22000 13000 28000 28000 13000 26000 12000 20000 24000 11000 19000

Kawasaki (on LHS)

BMW

Honda

Used by KTM & Yamaha

20 20 20 20 30 30 30 30

42 42 42 42 47 47 47 47

12 12 12 12 9 9 9 9

9,95 9,95 9,95 9,95 7,28 7,28 7,28

5 5 5 5 4,55 4,55 4,55

212 212 212 212 212 212 212

38000 38000 38000 30000 30000

19000 11000 24000 24000 19000 8500 15000

Note XT660r 2004 to 2008 uses NSK 6203z Wheel bearings

Mass

Designation

NSK

g

* - SKF Explorer

0,15 0,15 0,11 0.11 0,15 0,17

30205 J2/Q 320/28 X/Q 32005 X/Q L 45449/410/Q 320/28 X/Q 32006 X/Q

HR320/28XJ

45 45 45 45 45 45 45 65 64 65 65 65 65 65 65 32 32 39 39 39 39 39 39 39 52 38 38 38 69 69 69

6202 * 6202-2RSH * 6202-2RSL * 6202-2Z * 6202-RSH * 6202-RSL * 6202-Z * 6203 * 6203 ETN9 6203-2RSH * 6203-2RSL * 6203-2Z * 6203-RSH * 6203-RSL * 6203-Z * 16003 * 16003-2Z 6003 * 6003-2RSH * 6003-2RSL * 6003-2Z * 6003-RSH * 6003-RSL * 6003-Z * 63003-2RS1 61904 61904-2RS1 61904-2RZ 6004 * 6004-2RSH * 6004-2RSL * Also known as 6904

69 69 69 69 51 51 51

6004-2Z * 6004-RSH * 6004-RSL * 6004-Z * 61906 61906-2RS1 61906-2RZ 61906-2RS1 Also known as 6906