Fork maintenance

KTM and Husaberg Fork General Description (DVD: F125SX03D)
The Service manual recommends that the fork oil and seals should be replaced each year. Fork valves and shims are changed to set the suspension to match your weight, riding style and the type of riding you prefer. I don’t know about you, but I can’t afford to pay a shop $100 or more every year to keep your fork oil fresh and more than $200 for suspension modifications. The cost of the oil, seals, shims and valves are relatively inexpensive. Most of the cost is the shop labor. Wouldn’t it be nice if you could do it yourself with confidence just like the pro’s do? We’ll show you how to maintain your fork for a fraction of one service charge and possibly in less time than it takes to drop off and pick up your bike from the shop. Just think how much you’ll save if you ride competitively!

This DVD is designed for those who prefer watching a demonstration rather than reading a manual or fumbling your way through the process. After watching our detailed step-by-step video, you should be able to service your forks in approximately 3 hours if you possess moderate mechanical skills.

We’ll show you how to do this in your garage with minimal special tools. The mechanic speaks slowly so you can watch the video and take notes if you like. Unlike most maintenance videos that focus on the actor, this video is shot at close range so you can see the details. You can see each part through disassembly and reassembly. No steps are skipped.

What you’ll get:
A detailed video performed by a certified motorcycle mechanic on a 2003 KTM 125 SX.
Check www.racetech.com or email us if you are unsure of your fork model

What you'll need:
Tools and Supplies

This DVD contains the following:

A DVD sectioned into chapters so you can find information quickly (Fork removal, disassembly , Fork replacement)
Detailed tool list
How to remove the tire, brake and forks from the motorcycle
How to disassemble and clean the forks
Basic operation of the fork valves, shims and clickers
Description of valve and shim replacement
How to replace the fork seals and fork wipers
Complete reassembly
Proper oil filling and air bleeding procedure
Proper fork re-installation procedure.

Specific torque settings.
Consult your service manual since this procedure applies to many motorcycles and your bike may contain aftermarket parts.
Recommendations on shim modifications –
We recommend you talk with your local shop or consult racetech, ktmtalk.com or thumpertalk.com since riding preference and trail conditions need to be factored into the decision.

People learn faster from and instructional DVD than from reading a repair manual.
You’ll be more confident of doing the task after watching a professional than you would be after reading the service / repair manual.
Service / repair manuals don’t show you how to make your own tools. Some of our instructional
DVD’s show you how to make inexpensive tools.
Service / repair manuals don’t go into the same detail as found in the DVD.
The DVD applies to more types of bikes than the service / repair manual covers.
You can preview the level of effort required to do the job before you start. This is difficult to assess with the service / repair manual.
The service / repair manual generally shows one way to do the task. When applicable, the DVD will show several ways.
Sometimes the service / repair manual recommends removing parts (Radiators / carburetors) that aren’t necessary to be removed to do the procedure correctly.
The service / repair manual doesn’t describe how the parts operate. The DVD describes how some parts operate.
We recommend using the motorcycle repair or service manual as a reference for specifications.
However, there’s nothing better than watching someone do the procedure.
The repair manual just isn’t as good as a video when it comes to showing and describing a process.

Savings estimate
Procedure	LABOR cost per occurrence	Estimated occurrences per year	Estimated time it will take to do the procedure after watching the video	Video cost	3 year savings
Fork oil, Fork seals, and Fork valves	$215.00	1	2.5 hours	$39.95	$605.05