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'05 KTM forks interchangeability

  1. #1
    Backwoods lobster boy number9's Avatar
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    '05 KTM forks interchangeability


    What tubes will fit my '05 300 EXC forks?

    I sent my forks out to Factory Connection in NH and unfortunately the top outer tube from the left fork is junk and the inner tube from the right fork is close to junk.

    They're working with KTM & WP trying to find replacement parts but they're not having much luck. Rocky Mountain ATV seem to carry them, but I'd be spending almost $800 just replacing these two tubes. These are 48mm open-chamber forks from WP.

    If I'm hunting for spare parts, can I use tubes from a 200 or 250 EXC or similar? Any other bikes from any other years? Looking at the KTM parts fiche, the tube part numbers are 48600381E and 48601052 but it seems like they're only used on bikes in 2005. I'm sure other years and models will interchange, but the question is: which ones?

    I've posted on KTMtalk but I'm not having much luck..

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  2. #2
    Lifer typeone's Avatar
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    Re: '05 KTM forks interchangeability

    just a whisper but... can you do a KYB swap from an early Italian Husky or maybe Yamaha? it's all the rage in the Beta scene... but you'll need to track down specs. no help, i understand, but this might be an opportunity to go KYB up front. (which is more betterer)

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    Lifer Chippertheripper's Avatar
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    Re: '05 KTM forks interchangeability

    Aye.
    How are the tubes jacked up?
    Just a quick sniff on fleabay doesn't yield too many promising results.
    My only actual recommendation is to call Cliff's and ask Neil if he knows if anybody has some take offs as extras. Because sometimes dudes will swap front ends to keep their old set up forks or whathaveyou.

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  4. #4
    Backwoods lobster boy number9's Avatar
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    Re: '05 KTM forks interchangeability

    Quote Originally Posted by typeone View Post
    just a whisper but... can you do a KYB swap from an early Italian Husky or maybe Yamaha? it's all the rage in the Beta scene... but you'll need to track down specs. no help, i understand, but this might be an opportunity to go KYB up front. (which is more betterer)
    I could, but I don't love the idea because I've already got the right springs and valves in the forks that are in there now. If anything, people have suggested going to a later WP fork, like a 4CS. But I'm probably too slow to notice a difference...

    Quote Originally Posted by Chippertheripper View Post
    Aye.
    How are the tubes jacked up?
    Just a quick sniff on fleabay doesn't yield too many promising results.
    My only actual recommendation is to call Cliff's and ask Neil if he knows if anybody has some take offs as extras. Because sometimes dudes will swap front ends to keep their old set up forks or whathaveyou.
    The upper tube has been dented, cracked and welded badly. FC say it's a safety hazard. The previous owner covered it up with a fork protector... the lower tube has been dented and dinged. They polished the ding out but the dent is enough to slowly leak oil over time.

    eBay has a couple of options, but I want to be sure before shelling out money on something that I might not be able to even use. Good idea on the take-offs, I'll give that a try.

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    Lifer Kurlon's Avatar
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    Re: '05 KTM forks interchangeability

    I'll see what I can figure out for you tomorrow, I've had my head up Yamaha service manuals and parts lists for too long today, suspect I'm going to be doing a head swap... so I'm not in a google-fu mood at the moment. I bet there are a TON of machines you can source parts off of though.

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  6. #6
    Backwoods lobster boy number9's Avatar
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    Re: '05 KTM forks interchangeability

    Quote Originally Posted by Kurlon View Post
    I'll see what I can figure out for you tomorrow, I've had my head up Yamaha service manuals and parts lists for too long today, suspect I'm going to be doing a head swap... so I'm not in a google-fu mood at the moment. I bet there are a TON of machines you can source parts off of though.
    I trolled through some parts fiches and this is what I found:

    02 outer tube: 48600001
    02 inner tube: 48600002
    02 dust seal: 48600816
    02 guiding ring: 48600016
    02 guiding bush: 48601008
    02 oil seal ring: 48600057

    03 outer tube: 48600244
    03 inner tube: 48600240
    03 dust seal: 48600816
    03 guiding ring: 48600016
    03 guiding bush: 48601008
    03 oil seal ring: 48600347

    04 outer tube: 48600244
    04 inner tube: 48600240
    04 dust seal: 48600816
    04 guiding ring: 48600016
    04 guiding bush: 48601008
    04 oil seal ring: 48600347

    05 outer tube: 48600381E
    05 inner tube: 48601052
    05 dust seal: 48600816
    05 guiding ring: 48600016
    05 guiding bush: 48601008
    05 oil seal ring: 48600399

    06 outer tube: 48600693
    06 inner tube: 48600437
    06 dust seal: 48600816
    06 guiding ring: 48600016
    06 guiding bush: 48601008
    06 oil seal ring: 48600399

    If the dust seal, ring and bush part numbers are always the same, does that mean the fork tubes are functionally the same? I don't care if they're different colors...

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    Lifer Kurlon's Avatar
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    Re: '05 KTM forks interchangeability

    Looking like most 300 EXCs are all sporting the same base inner and outer tubes. Your 05 for example has had those PNs superseded by the 08 300 EXC bits.

    Looks like $580 for an inner and outer new off Motosport.com. Unfortunately I can't find a comprehensive list of what machines ran what fork type (open chamber, closed chamber, chamber pot, etc) when for KTMs. I do see you've started a thread on KTM Talk, likely your best option for sourcing info.

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  8. #8
    Backwoods lobster boy number9's Avatar
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    Re: '05 KTM forks interchangeability

    Quote Originally Posted by Kurlon View Post
    Looking like most 300 EXCs are all sporting the same base inner and outer tubes. Your 05 for example has had those PNs superseded by the 08 300 EXC bits.

    Looks like $580 for an inner and outer new off Motosport.com. Unfortunately I can't find a comprehensive list of what machines ran what fork type (open chamber, closed chamber, chamber pot, etc) when for KTMs. I do see you've started a thread on KTM Talk, likely your best option for sourcing info.
    Thanks Kurlon. This information has been surprisingly hard to find in one place. WP themselves said "Any '05+ big bike to current" would work, but other dealers have said it's '03-'15. I haven't found a concrete answer on KTMtalk so far either.

    I'm not a suspension designer, but I don't see how you can use just one set of dust seals, oil seals and bushings across a variety of different tube part numbers if the tubes themselves aren't dimensionally identical.

    $580 is better than $800, but not much better.

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  9. #9
    Lifer Kurlon's Avatar
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    Re: '05 KTM forks interchangeability

    Well, the sliding surfaces may be the same, but there is a lot more to those tubes than the sliding surfaces. You've got different axle lugs to contend with (KTM doesn't sell the tube separate from the lug IIRC), overall lengths can differ, etc. So there is room for shenanigans. If you don't find a cheap source, snag a used set off ebay.

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