KTM 500 EXC - Installing the Fork Legs; Removing the Fork Protector

11 SERVICE WORK ON THE CHASSIS 47
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– Release screws 4. Take out the left fork leg.
– Release screws 5. Take out the right fork leg.
11.8 Installing the fork legs x
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Main work
– Position the fork legs.
Info
Grooves are milled into the side of the upper end of the fork legs. The sec-
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
Position bleeder screws 1 toward the front.
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– Tighten screws 2.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
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– Position brake caliper, and mount and tighten screws 4.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite
®
243™
– Mount cable binder 5.
– Position the brake line, wiring harness, and clamp. Mount and tighten screws 6.
Finishing work
–
Install the front wheel. x ( p. 74)
– Refit the headlight mask with the headlight. ( p. 83)
– Check the headlight setting. ( p. 85)
11.9 Removing the fork protector x
Preparatory work
– Remove the headlight mask with the headlight. ( p. 83)
– Raise the motorcycle with the lift stand. ( p. 45)
–
Remove the front wheel. x ( p. 74)
– Remove the fork legs. ( p. 46)