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
Index
Description
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
Models with 4357MXMA Forks
Dia
No
Part No
Description
S=Standard
E=Enduro
X=Option / As Required
SM=SuperMotard
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
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
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
400/520
SX/MX
2000-02
620/625
SX
2000-05
295
260
295
260
S
S
S
S
S
S
S
S
S
S
S
S
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
Dia
No
Part No
Description
Qty
Cost
Nov 09
US
Cost
Nov09
Aus
$78.66
$4.17
$7.78
$1.93
$3.69
$1.93
$1.93
$1.93
$3.75
$5.13
Wire Rate Length

Dia
mm n/mm mm
250-380
SX/MX
2000-02
Price is for a pair
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
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
$4.99
$0.99
$2.99
$0.99
$0.99
$0.99
$1.99
$2.99
$6.99
$13.99
$14.99
$6.99
$22.99
$30.99
$11.87
$23.18
$23.18
$10.83
$42.01
$42.63
now 4860.0053
was 4860.0039
512
492
S01
S
S01
S 02
X
X/?
S
X/S
X/S
X/S
S01
S02
S
S01
S02
S
S 03-05
S 03-05
S 03-05
S
SM
S-01
S-02
S 03-05
Dia
No
Part No
Description
Qty
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
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
Spring
Spring
Spring
Spring
Spring
Spring
Spring
Interm Ring 26,2x38,5x3
Screw Sleeve m29,3x1
DU Bush 14x16x12
O-Ring 8x1.25
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
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
$12.99
$53.99
$62.99
$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
400/520
SX/MX
2000-02
S
S
S
S-01
S01
S02
X
X
X
S
X
X
X
X
X
S
X
S
S-01
S
S
S-01
S-01
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
S-01
S 02
S01
S02
S-01
S01
S02
S-01
S-02
S 03-05
S-01
S 02-05
Dia
No
Part No
Description
Qty
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
4054.1408
4054.1414
4054.1416
4357.0120
4860.0062
4860.0068
4860.0215
4860.0216
4860.0042
4860.0060
Shim 6x8.0x0.3
Shim 6x8.0x0.1
Shim 6x8.0x0.3
Shim 8x18x0.1
Check Valve 8x24x0.1
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
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
Cost
Nov 09
US
$1.99
$1.99
$1.99
$8.99
$3.99
$3.99
$5.99
$5.99
$48.99
$4.99
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
$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
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
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
620/625
SX
2000-05
X
X
S
S
S
S
S
S
S
S
S
S
S
S 01-02
S
S
S
S 01-02
S
S
now 4357.201
S
S
S
S
now 4357.202
S
S
S
S
See Shim List below

577
577
2001-2 Models
2003 onwards
2001-2 Models
2003 onwards
585
585
390
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
Dia
No
Part No
Description
Qty
58
59
60
60
60
61
61
62
62
63
63
64
64
70
70
71
72
50
69
69
69
82
99
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
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
Check Valve Nut 6x0.5
Check Valve Nut 6x0.5 D=2
Shim 6x8x0.3
Piston Compression D=27.9
O-Ring 21x2
Shims as required
Tap Compression
Tap Compression D=35mm
Rubber Cap
Repair Kit 4357 MXMA
2
2
1
1
1
1
1
4
4
2
2
2
2
2
81
73
4860.0027s
4860.0152s
4860.0152s1
4860.0141
R510
Parts Breakdown for item 69 Above

4860.0004
Copper Washer 29.5x33.5x1
3548.0320
O-Ring 24x2
2
2
2
2
2
1
2
2
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
$1.99
$2.99
$2.84
$5.28
250-380
SX/MX
2000-02
400/520
SX/MX
2000-02
S
S
S
S01
S02
S
S
S
S
S
S
S
S
S
S
X02
S
S
S 00/01
S 02
S 00/01
S 02
S02
S
S
S
S
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
Dia
No
Part No
Description
Qty
74
74
75
75
75
80
5
6
76
79
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
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
400/520
SX/MX
2000-02
S 00/01
S 02
S 00/01
S 02
S
S
S
S
S
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
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
1
2
3
4
5
6
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
50
50
50
50
50
50
50
50
50
50
50
50
Part No
Description
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
Qty
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
$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
Wire Rate Length

Dia
mm n/mm mm
Also 4054.0470
Was 4054.0450
250-380
SX/MX
2000-02
400/520
SX/MX
2000-02
620/625
SX
2000-05
Dia
No
Part No
Description
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
50
50
50
50
50
50
50
50
50
50
50
50
50
Qty
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
50
50
49
49
49
49
49
49
49
49
50
Part No
Description
4860.0100
4860.0101
4860.0102
4054.0774
4860.0139
4860.0116
Shim 6x24x0.15
Shim 6x24x0.2
Shim 6x24x0.25
Cost
Nov 09
US
$3.99
$3.99
$3.99
Cost
Nov09
Aus
$4.15
$4.56
$4.56
Shim 6x18x0.1 Delta

Shim 6x22x0.1 Delta
Shim 6x24x0.1 Delta
$3.99
$3.99
$3.99
$5.32
$5.32
$5.32
2.99
5.99
7.99
$4.99
$4.99
2.99
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
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
Shim 8x10x0.20
Shim 8x11x0.2
Shim 8x14x0.10
Shim 8x14x0.25
Shim 8x16x0.1
Shim 8x16x0.20
Shim 8x18x0.1
Shim 8x18x0.4
4860.0212
Pressure Ring 20x16.25x0.20
Qty
$5.99
$4.99
19.99
3.99
$8.99
3.99
$5.99
$5.99
$5.99
$3.99
3.99
Wire Rate Length

Dia
mm n/mm mm
Was 4860.0067
Was 4860.0066
From 4860
250-380
SX/MX
2000-02
400/520
SX/MX
2000-02
620/625
SX
2000-05
Dia
No
Part No
Description
Qty
Cost
Nov 09
US
Cost
Nov09
Aus
Wire Rate Length

Dia
mm n/mm mm
Cost
Qty Nov 09
US
Cost
Nov09
Aus
Notes
Consumable Parts
Dia
No
Part No
Description
2
7
9
10
4860.0016
4860.0044
4860.0009
4860.0043
O-Ring 48x2
O-Ring 6x1.5
O-Ring 3.7x1.6
O-Ring 12x1.5
2
2
2
2
34
39
43
43
51
13
15
16
17
18
19
22
59
71
72
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
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
Lock Washer SB53
DU-Bush 43.8x43x20
O-Ring 41x2
O-Ring 21x2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
250-380
SX/MX
2000-02
400/520
SX/MX
2000-02
620/625
SX
2000-05
Protech
Source
FluidS
Fork Cap
$0.99
$0.99
$1.99
$4.17
$1.93
$1.93
$3.75
$1.30
$0.31
$0.47
$0.84
$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
$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
Damper
$0.29
$18.22
$18.18
2001-2 Models
$90.44
was 4357.0140
was 4357.0094
2001-2 Models
$59.36
$93.92
$1.77
$0.77
Dia
No
Part No
Description
Qty
81
73
76
79
4860.0004
3548.0320
4860.0049
4860.0051

O-Ring 24x2
O-Ring 8x2
Lock Washer RB12
2
2
2
2
Total
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
Lock Washer SB53
Dust Stripper 43mm
DU-Bush 43.8x43x20
DU-Bush 42x44x20
Inner Tube D=43mm
Inner Tube D=43mm
Cost
Nov 09
US
$1.99
$2.99
$3.99
$1.99
Cost
Nov09
Aus
$2.84
$5.28
$11.71
$2.19
$204.78 $335.11
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
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
$280.12
$7.16
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
Models with 4860MXMA Forks
Dia
No
Part No
Description
S=Standard
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
Suspension Travel
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
X=Option / As Required
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
295
295
950
990
Adv/S A, E, S
2003-5 2007
270/275 230/265
05210
215 ?
S 01/2
S 03-5
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S 01/2
S 03
S
S
Dia
No
Part No
Description
Qty
Cost
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
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
$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
$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
S
S 03-5
S 03-5
S
S 01
S
S
Adv S
S
S
S 02-5
S 03/4
S 05
S 01
S 02
S 01
S 02
Dia
No
Part No
Description
Qty
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
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
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
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
Part No
Description
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
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
Spring
Washer 32x42x2.5
Interm Ring 26,2x43x3
DU Bush 14x16x12
O-Ring 8x1.25
Rebound Spring D=15x11
Rebound Spring 34.5x15x11
Rebound Spring 34.5x15x11
Tap Rebound
Tap Rebound
Tap Rebound D=3
Spring Check Valve D=0,5
Shims as required
Check Valves as required
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
4860.0042
4860.0201
4860.0060
4860.0212
4054.0486
4860.0001
Qty
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
8
2
2
2
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
$48.99
$61.99
$4.99
$31.99
2
2
$4.99
$487.99

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 03/4
S 05
S
S
S
S
S
X
X
S
Dia
No
Part No
Description
Qty
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
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
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
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
Part No
Description
Qty
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
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
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
Check Valve Nut 6x0.5
Check Valve Nut 6x0.5 D=2
O-Ring 21x2
Shims as required
Tap Compression
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
4860.0027s
4860.0152s
4860.0152s1
4860.0141
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

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
Part No
Description
Qty
99
R140.07
Repair Kit 4360 MXMA
Cost
640
Nov 09 Nov09 Dia
SX
SX/EX
Adv
US
Aus
mm n/mm
2002 2003-4 2001-5
$284.99 $319.16
S
?
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
81
73
74
74
75
75
75
80
5
6
76
79
Parts Breakdown for item 69 Above

4860.0004
3548.0320
O-Ring 24x2
4860.0027
Tap Compression
4860.0152
Tap Compression
4860.0035
4860.0153
4860.0190
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
$2.84
$5.28
$67.31
$67.31
$8.35
$9.32
$15.46
$13.48
$1.93
$3.69
$11.71
$2.19
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
950
990
Adv/S A, E, S
2003-5 2007
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
Dia
Year
Disc
LHS
Disc
RHS
Pad
LHS
Pad
RHS
Disc
Type
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
400 EXC
450 EX/SX
2000-3 20.031W
2004-6 20.0377W
N/A
N/A
30.048
30.048
N/A
N/A
Solid
Solid
260
260
126
126
143
143
6
6
6.5
6.5
3.5
3
3
2.5
0
0
94
94
37.3
37.3
7.5
7.5
520 EX/SX
525 EX/SX
2000-1 20.031W
2004-5 20.0377W
N/A
N/A
30.048
30.048
N/A
N/A
Solid
Solid
260
260
126
126
143
143
6
6
6.5
6.5
3.5
3
3
2.5
0
0
94
94
37.3
37.3
7.5
7.5
620SC
620SC-SM
625SC
625 SXC
625 SXC
625 SXC
1996-02 20.357
2000-2 21.063
2002
20.031
2003
20.031
2004 20.0377W
2005-6 20.0377W
30.048
30.048
30.048
30.048
30.048
30.048
N/A
N/A
N/A
N/A
N/A
N/A
Solid
Floating
Solid
Solid
Solid
Solid
300
320
260
260
260
260
127
143
6.5
3.5
94
37.3
7.5
N/A
N/A
N/A
N/A
N/A
126
126
126
126
143
143
143
143
6
6
6
6
6.5
6.5
6.5
6.5
3.5
3.5
3
3
3
3
2.5
2.5
0
0
0
0
94
94
94
94
37.3
37.3
37.3
37.3
7.5
7.5
7.5
7.5
640LC4Adv
640LC4Adv
640LC4Adv
98-2000
2001-2
2003-7
20.357
21.063
20.384
N/A
N/A
20.385
30.048
30.048
30.048
N/A
Solid
300
N/A
Floating 320
30.048
Solid
300
127
143
6.5
3.5
94
37.3
7.5
127
143
6.5
4.5
690 Enduro & R 2008-9

690 SMR/SMC 2007-9
20.357
21.063
N/A
N/A
30.362
30.183
Solid
300
Floating 320
127
143
6.5
3.5
108.9 41.3
35
40.53
30.052
Solid
300
30.052 Floating 300
127
143
6.5
4.5
108.9
41.3
105
120
6.5
4.5
108.9
41.3
7.6
950 Adv & S

990 Adv
2003-5
2006-9
20.384
21.086
20.385
21.086
30.052
30.052
BMW F650
2000-7
20.223
N/A
30.362
Part No
N/A
N/A
N/A
Solid
300
KTM Front Disc Caliper & Wheel Information from online Fiche & Parts Diagrams
Description
Price
Price
0
7.6
7.4
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
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
$42.99
$4.99
$2.99
$19.99
$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
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
$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
$99.99 $163.17 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.049.000

20
8
2
7
21
$62.99
$13.99
$270.99
$15.99
$11.99
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
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
BMW F650GS
Disc Fixed 300mm
$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
$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
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
KTM
KTM
Usage
Price
$US
Price
$A
Rebound
Rebound
KTM
KTM
KTM
KTM
KTM
KTM
KTM
9501.0010s
9501.0001s
9501.0002s
9501.0003s
9501.0004s
9501.0012s
9501.0022s
IKON
500-150
WP43
WP43
WP43
WP43
WP43
WP43
WP43
Teknik
Teknik
19-130-36to52
19-130-66
SX/MX/EX 01-02
SX/MX/EX 01-02
Teknik
Teknik
YSS
19-135-46
19-135-50
1622-216
Kawa KLX 250/300

Kawa KLX 250/300
BMW
TT
Spec
Rate
n/mm
21
19
5.39
0.53
3
2
3.6
3.8
4
4.2
4.4
4.4
5
4.6
4.75
4.75
4.9
4.9
4.9
5
4.9-5.5
40
200
4.75
4.75
4.75
35
33
33
166
157
157
38
KTMEXC-01WJC
KTMEXC-01WJC
WJC Play Calc
KTM
KTM
WJC
$189.00
$189.00
Spring Calcs
Dia Weight Coils Preload Comp
mm
Length
OD Length
22.5
34.5
510
38.5
490
38
38
38
508
485
415
38
38
510
510
0.36 to 0.52
0.66
462
462
0.46
0.5
467.9
6.2
$189.00 38.6
$189.00 38.6
$179.00
3
7
9
14
36.5
34.6
37.1
173
35.5
BMW
Tested
34
477
Fork Springs WP4860
46.5
20
232.5
Spring Calcs
Mfr
Part No
Usage
Teknik
Teknik
19-165-36to52
19-165-66
SX 2007
SX 2007
Teknik
Teknik
Teknik
19-180-38to50
19-180-58
19-180-60
Teknik
19-190-36to54
Eibach
974.048.1
KTM
KTM
KTM
KTM
KTM
KTM
KTM
KTM
KTM
KTM
9141.0011s
9141.0012s
9141.0013s
9141.0014s
9141.0015s
9141.0016s
9141.0017s
9141.0020s
9141.0040s
9141.0045s
Price
$US
Price
$A
OD Length
Rate
n/mm
$189.00 43.5
$189.00 43.5
461
461
0.36 to 0.52
0.66
04-06 640/950, 08 SX
04-06 640/950, 08 SX
04-06 640/950, 08 SX
$189.00
$189.00
$189.00
43
43
43
485
485
485
0.38 to 0.50
0.58
0.6
02-04 SX, 03-09 EX
$189.00
43
505
0.36 to 0.54
43.2
508
0.48
WP48
WP48
WP48
WP48
WP48
WP48
WP48
WP48
WP48
WP48
3.6
3.8
4
4.2
4.4
4.6
4.8
4.8
4.8
5.9
Dia
mm
5
5.1
5.25
5.25
5.5
Coils Preload Comp

Length
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
NA
1.28
2.33
4.76
4.65
0.20
NA
NA
0.37
3.46
1.73
0.98
0.16
1.11
2.40
4.76
4.65
0.39
NA
NA
0.37
3.46
1.73
0.98
0.34
0.70
1.20
4.23
4.03
NA
0.15
0.16
0.33
3.41
1.54
1.11
Totals
Weight Savings
Forks, Brace & Axle
19.74
20.00
13.58
13.84
17.20
2.80
11.14
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)
0.086
0.080
NA
NA
NA
0.086
0.080
NA
NA
0.110
0.086
0.058
0.040
0.102
0.110
0.040
0.050
0.830
0.040
0.150
0.040
0.050
0.830
0.032
0.150
0.025
NA
0.618
0.080
NA
Upper Yoke Total Weight
1.276
1.378
1.119
Ring (BMW) / Seal (KTM)

Lower Yoke & Post
Lower Yoke Pinch Bolts 4
2.330
0.080
2.330
0.064
1.103
0.064
0.00
19.74
0.00
Component Detail
Page 39
0.000
Weight
Horn Mount, Bolt & Spacers
0.060
0.060
0.060
Lower Yoke Weight
2.470
2.454
1.227
Fork Cap / Adjuster

Adjustment Tube
Preload Spacers
Spring
Hydra Stop
Damper Rod / Damper CPL
Staunchion / Upper Leg
Upper DU Bush
Fork Seals & Rings
0.132
NA
0.010
0.662
NA
0.310
2.020
0.133
NA
0.080
0.662
NA
0.310
2.025
0.055
0.055
0.115
0.022
0.016
0.518
0.093
0.492
1.280
0.042
0.046
Upper Complete 3.210
6.378
6.530
5.248
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
0.200
0.040
0.090
0.020
0.060
0.960
0.960
NA
NA
NA
0.206
0.030
0.093
NA
NA
NA
0.060
1.045
0.950
NA
0.015
NA
0.038
1.055
1.064
0.460
0.300
0.146
2.330
2.399
3.063
0.000
12.454
12.761
10.657
0.000
Total Fork Weight

Axle
RHS Wheel Spacer
Front Wheel
Caliper Hanger & Bolts
Disc Caliper
LHS Disc
LHS Wheel Spacer
Axle Nut
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
0.000
0.000
0.286
0.010
3.410
0.235
0.875
1.540
0.010
0.016
Front Wheel Total Weight
6.597
6.612
6.382
0.000
Total Front End Weight
19.051
19.373
17.039
0.000
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
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)
Mid Valve
4860.0480
4860.0213
4860.0351
49
49
49
49
4860.0213
4860.0068
4860.0215
4860.0216
4860.0062
49 4054.1414
49 4054.1408
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
Shim 6x8.0
0.1
Shim 6x8.0
0.3
Standard 640 Adv

2002 2003 2005
154
158
24
178
4.4
24 22.75
182 181
4.4
4.6
4
5
5
120
158
?
0.40
1.20
640Adv Mod
02
03
154
91
24
269
5
5
5
100
1
1
5
100
Shims Reqd
Shims Available
You1 You2 EXC Buy Spare
168 165
65
65
15.75 15.75
249 246
4.6
4.6
5
5
5
5
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
Mid
Mid
2.15
1.00
1.15
2.15
1.15
1.00
1.95
0.40
1.55
X
X
?
0.70
1.80
?
0.70
2.50
X
?
?
0.95 #####
1.05 1.13
1
158
86
24
268
5
F650 F650
You1 You2
1
1
1
4
?
?
1
1
1
4
?
?
2
1
4
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
2
2
2
2
2
2
4
2
2
1
3
1
3
1
3
2
6
2
6
?
?
0
2
0
2
2
2
1
?
?
2
2
2
1
2
#####
#####
#####
#####
#####
#####
#####
#####
#####
#####
2
#####
#####
4
1
1
Dia Part No
Description
Thick
No
ness
Rebound Valve
45 4860.0025 Rebound Tap Fitted
Standard 640 Adv

2002 2003 2005
640Adv Mod
02
03
50
50
50
50
50
50
50
50
50
50
50
50
55
Rebound Piston
Length Available
Stack Size
Free Length
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
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.15
0.1
0.1
0.3
0.25
1.45
1.45
1
1
1
1
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
1.3
0.95
X
2.25
1.4
0.85
exc300
As Rx
1
1
1
1
1.55
1.4
1
1
1
1
1
1
1
2
1
1
1
2
2
2
2
4
2
2
2
1
1
1
1
1
1
1
X
27
2.05
3.9
3.6
19.5
2.05
12
6.7
2.85
X
1.4 ?
1.4
X
2.45
1.4
4
2
2
2
2
2
2
1
1
1
1
1
#####
1
1
1
X
Shims Reqd
Shims Available
X
X
Valve Shaft Length

Nut Spring Base Recess Depth
10 mm Valve Section Length
Valve Piston 8mm Instep (on top side)
Valve Piston Thickness
Rebound Nut Length
Max Rebound Valve Length
52 4860.0042
F650 F650
You1 You2
2
1
1
1
X
1
#####
#####
1
1
X
1
1
X
1
1
X
1
1
X
2
2
X
2
2
X
2
2
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
71
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
74
74
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
640Adv Mod
02
03
1.85
X
1.85
X
1.85
X
1.85
5
1.6
2
1
1.3
2
1
1.85 1.85
X
X
#####
1.95 1.85
6
6
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
F650 F650
You1 You2
6.5
3.8
1.55
1
16.5
6.5
3.8
1.55
1
16.5
1.85
8.9
1.6
1.35
2
1.85
8.9
1.65
1.3
2
1
1
1
1
1
1
1
1
1
1
1
1
Shims Reqd
Shims Available
X
4
2
2
2
2
2
2
6.5
3.8
1.55
1
16.5
4
2
1.85
8.9
1.6
1.35
2
4
2
1
2
1
1
1
1
#####
#####
1
1
1
1
1
1
2
1
X
X
#####
#####
#####
#####
#####
3
1
X.
#####
2
2
2
2
1
1
#####
2
2
2
2
2
2
exc300
As Rx
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
4054.0774 Shim 6x18x0.1 Delta

50 4860.0139 Shim 6x22x0.1 Delta
50 4860.0116 Shim 6x24x0.1 Delta
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
$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
$3.99 $5.32
$3.99 $5.32
$3.99 $5.32
4054.0774 Shim Triangular 6 x18

$3.99 $5.32
$3.99 $5.32
$3.99 $5.32
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
4860.0555
4860.0068
4357.0120
4054.0477
4860.0215
4860.0216
4860.0384
4860.0062
4860.0061
19.99
3.99
$8.99
3.99
$5.99
$5.99
$5.99
$3.99
3.99
49
49
49
49
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
$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
50
50
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
4054.0477
49 4357.0120
4860.0061
49 4860.0062
4860.0068
4860.0213
49 4860.0214
49 4860.0215
49 4860.0216
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
$3.75
$3.75
$3.42
$6.45
$4.56
$4.56
$4.56
$2.99 $4.56
50
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
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
$6.45
$10.76
$5.32
$5.32
$5.88
$5.88
$5.32
$5.69
49
49
49
50
50
50
50
50
50
50
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
7.99
$4.99
$4.99
$4.99
5.99
$5.99
$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
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
?
?
?
?
?
?
?
?
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
24x0.1
24x0.1
Springs Fitted
Rebound Valve
45
47
49
49
49
49
4860.0025
Tap Rebound
3548.0377 Spring Check Valve D=0.5
4860.0062
4860.0062
4860.0062
4860.0062
52
51
4860.0042
4860.0060

Piston Ring 5x1x84
50
50
4860.0116
4860.0116
Shim 6x24x0.1 Delta

Shim 6x24x0.1 Delta
50
50
50
50
50
50
50
50
4054.0401
4860.0139
4860.0065
4054.0403
4054.0402
4054.0405
4054.0447
4054.0414
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
55
4054.0486
Nut Rebound m6x0.5
24dx0.1
24dx0.1
14x0.1
22x0.1
20x0.1
17x0.1
14x0.1
12x0.1
10x0.2
10x0.2
Compression Valve
63
64
70
4860.0163 Check Valve Nut 6x0.5 D=2

4860.0202 Spring Check Valve D=0.5
4860.0061
1
1
1
71
72
4860.0047 Piston Compression D=27.9

4861.1499
O-Ring 21x2
1
1
50
4860.0063
Shim 6x24x0.1
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
24x0.1
19x0.1
17x0.1
15x0.1
14x0.1
13x0.1
12x0.1
11x0.1
9x0.3
69 4860.0152s1 Tap Compression D=35mm
Page 49
Husa
Page 50
Husa
Page 51
Spring Calcs
F650GS
Yourf650
Yamaha
KTM
YZF426 300EXC
2001
2001
KTM
640LC4
2003
KTM
640Adv
2001-3
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
107
1.2&1.2
102
0.8&1.3
1.9
11
8.25
112.15
149
2.1&1
2.575
11
8.25
159.825
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
4.2
4.4
5
150
6
150
Machine
7
5.25
112.25
4.6
462
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
F650GS
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
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
0.409
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
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
190
195
200
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
Notes
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
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
Volume Calculations
ID of Tube
IR of Tube
Avail
10
5
15
7.5
19 avail
20
10
25
12.5
Area of Tube
78.54
176.71
314.1592654
490.874
Length of Tube
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 Comparison

1.200
WJC Weight
0.622
0.635
0.648
1.000
1.1059322
1.10082305
0.800
1.09819639
Spring Rate
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
0.600
0.400
0.200
0.000
342
364
386
408
430
452
474
496
518
540
562
584
Total Machine & Rider Weight - lbs
606
628
650
672
Fork Volume
44
22
49
24.5
1520.53084
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
YZF426
300EXC
640LC4DS
640AdvR
950Adv
672
694

1
0.95
0.9
0.85
0.8
Spring Rate - kg/mm
0.75
F650GS
0.7
YZF426
300EXC
0.65
640LC4DS
640AdvR
0.6
950Adv
0.55
0.5
0.45
0.4
0.35
0.3
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
Rider Weight - kgs

1.050
1.000
0.950
0.900
0.850
Spring Rate - kg/mm
0.800
0.750
F650GS
YZF426
0.700
300EXC
640LC4DS
0.650
640AdvR
950Adv
0.600
0.550
0.500
0.450
0.400
0.350
0.300
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
Total Machine & Rider Weight - Kgs
1.050
1.000
0.950
0.900
0.850
Spring Rate - kg/mm
0.800
0.750
F650GS
YZF426
0.700
300EXC
640LC4DS
0.650
640AdvR
950Adv
0.600
0.550
0.500
0.450
0.400
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
25
28
52
52
16,25
16
30,8
31,9
33,5
38
3,45
4
10000
10000
13000
13000
Honda
25
47
15
27
32,5
3,25
11000
14000
KTM 640
29
50.292
14.224
26
32.5
3.35
10000
14000
Yamaha
???
28
30
52
52
16
17
31,9
35,8
38
44
4
4,55
10000
9000
13000
12000
15
15
15
15
15
15
15
35
35
35
35
35
35
35
11
11
11
11
11
11
11
8,06
8,06
8,06
8,06
8,06
8,06
8,06
3,75
3,75
3,75
3,75
3,75
3,75
3,75
160
160
160
160
160
160
160
43000
43000
43000
43000
43000
28000
13000
22000
22000
13000
28000
28000
17
17
17
17
17
17
17
17
40
40
40
40
40
40
40
40
12
12
12
12
12
12
12
12
9,95
11,4
9,95
9,95
9,95
9,95
9,95
9,95
4,75
5,4
4,75
4,75
4,75
4,75
4,75
4,75
200
228
200
200
200
200
200
200
38000
38000
38000
38000
38000
38000
24000
24000
12000
19000
19000
12000
24000
24000
17
17
17
17
17
17
17
17
17
17
35
35
35
35
35
35
35
35
35
35
8
8
10
10
10
10
10
10
10
14
6,37
6,37
6,37
6,37
6,37
6,37
6,37
6,37
6,37
6,05
3,25
3,25
3,25
3,25
3,25
3,25
3,25
3,25
3,25
3,25
137
137
137
137
137
137
137
137
137
137
45000
45000
45000
45000
45000
45000
45000
-
28000
22000
28000
13000
22000
22000
13000
28000
28000
13000
20
20
20
37
37
37
9
9
9
6,37
6,37
6,37
3,65
3,65
3,65
156
156
156
43000
43000
26000
12000
20000
20
20
20
42
42
42
12
12
12
9,95
9,95
9,95
5
5
5
212
212
212
38000
38000
24000
11000
19000
Wheel Bearing Info
Kawasaki
(on LHS)
BMW
Honda
Used by
KTM &
Yamaha
20
20
20
20
42
42
42
42
12
12
12
12
9,95
9,95
9,95
9,95
5
5
5
5
212
212
212
212
38000
38000
38000
19000
11000
24000
24000
30
30
30
30
47
47
47
47
9
9
9
9
7,28
7,28
7,28
4,55
4,55
4,55
212
212
212
30000
30000
19000
8500
15000
Note XT660r 2004 to 2008 uses NSK 6203z Wheel bearings
Mass
Designation
* - SKF Explorer
0,15
0,15
30205 J2/Q
320/28 X/Q
0,11
32005 X/Q
0.11
L 45449/410/Q
0,15
0,17
320/28 X/Q
32006 X/Q
45
45
45
45
45
45
45
6202 *
6202-2RSH *
6202-2RSL *
6202-2Z *
6202-RSH *
6202-RSL *
6202-Z *
65
64
65
65
65
65
65
65
6203 *
6203 ETN9
6203-2RSH *
6203-2RSL *
6203-2Z *
6203-RSH *
6203-RSL *
6203-Z *
32
32
39
39
39
39
39
39
39
52
16003 *
16003-2Z
6003 *
6003-2RSH *
6003-2RSL *
6003-2Z *
6003-RSH *
6003-RSL *
6003-Z *
63003-2RS1
38
38
38
61904
61904-2RS1
61904-2RZ
69
69
69
6004 *
6004-2RSH *
6004-2RSL *
NSK
HR320/28XJ
Also
known as
6904
69
69
69
69
6004-2Z *
6004-RSH *
6004-RSL *
6004-Z *
51
51
51
61906
61906-2RS1
61906-2RZ
61906-2RS1
Also known as 6906

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Index

See Notes below

Part No's extracted from spare parts manuals

Models with 4357MXMA Forks

2000 to 2002 - 250, 300, 380 SX, MX, EX

Wire Rate Length

Front Suspension Travel

Handlebar Clamp D=22mm

Fits all SX/EX/MX

Wire Rate Length

Price is for a pair

Parts Breakdown for item 4 below

Screw Cap m51x1.5

Wire Rate Length

See Shim List below

Tube 29.3x1x385 ALU

Parts Breakdown for item 69 Above

Available Shim List

Wire Rate Length

Wire Rate Length

Shim 6x18x0.1 Delta

Pressure Ring 20x16.25x0.20

Wire Rate Length

Wire Rate Length

Copper Washer 29.5x33.5x1

Outer Tube D=54/57

Wire Rate Length

Part No's extracted from spare parts manuals

Models with 4860MXMA Forks

2003 onwards - 250, 300, 380 SX, MX, EX

Top Triple x=20 d=54 SX

$250.45 same as 4357 forks

Parts Breakdown for item 4 below

Screw Cap m51x1.5

Cost Wire Rate Length 400-520 450/525

Outer Tube D=54/60

Inner Tube D=48mm

Cost Wire Rate Length 400-520 450/525

Repair Kit 4360 MXMA

Parts Breakdown for item 69 Above

KTM Front Disc & Brake Pad Information

690 Enduro & R 2008-9

950 Adv & S

4357 20mm Axle & Hub Information Listed in assembly order R to L

Axle Front USD43 2001 185mm

15 0015.080353 Collar Screw Caliper 8x35

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

125-525 SX 2001-2 + 625 SX to 2005 No speedo pickup

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

$99.99 $163.17 640Adv 04 & 950/990 2003 to 2006 Replaced by 601.13.049.000

Wheel Spindle Front 2003

24 590.09.062.013 Disc Rotor Collar Screw 6x13 10.9

Disc Fixed 300mm

640 & 950/990 2003 to 2008

Caliper 2 piston floating 30/32

Brembo 22.5553 Hanger 22.5554

58413014000 2005 SX Super Moto 320mm Disk support

Fork Springs WP4357