'05 KTM forks interchangeability

[number9]

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..

[typeone]

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)

[Chippertheripper]

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.

[number9]

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...

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.

[Kurlon]

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.

[number9]

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...

[Kurlon]

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.

[number9]

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.

[Kurlon]

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.