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Suspension upgrades

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5.9K views 24 replies 6 participants last post by  grantmotox  
#1 ·
Been a while since I've been on here, also a bit out of touch on this subject. Got a 17 EXC250, had it a while, bike is spot on, except the suspension which frankly is fucking awful. I do need to check/adjust the sag and clickers as I've shrunk a bit since I first bought it but it's never been great. The rear is like a pogo stick, I think that could be improved a little with some adjustment tbf. The forks though, I find myself holding on to the bars for grim death to point the thing where I want to go. I rode west harting down yesterday, it's a nadgery little loop tbf but the forks do nothing to inspire confidence. You really seem to have to fight the bike rather work with it. My old wr was brilliant like that, if you got something a bit wrong it'd just deal with it and soak it up, the ktm not so much!

I've seen a post about fork inserts that tbf, for my level of riding I just can't justify the price of. Are there any other options to improve the things without spending a fortune? More so the forks but the rear shock as well, I think I've heard of people upgrading the innards of those too?

Cheers

Cameron
 
#2 ·
You’ve had KYB on the WR. The only way you’ll get near that feeling again is spending the money. Standard WP forks are absolutely hopeless compared to what you had before. If you could see the internals of each fork laid on a bench you’d think the WP has lost lots of parts. The reality is they have. They are 1950s tech (fixed orifice damping). Built cheap.
 
#8 ·
as the bike is a 17, a good service is a good starting point.
Service, correct springs and sag. You could go for a K-tech ORVS kit in the front if you want a bit more control
Sorry forgot I put this post up until today where I thought the bars were gonna tear my arms out of their sockets. Rode a TnT day, fast open stubble field stuff. Loads of braking and accelerating bumps. It was basically bad everywhere but particularly when hard on the brakes at the end of a straight, I mean you'd get a bit out of shape on the best of suspension but that near on had me over the bars lol. Going back to the whole kayaba suspension thing, I rode my mates 53 wr450, never ridden the thing in anger before and the difference is unbelievable, easily did my fastest lap on it, a bike I did one lap on and don't know at all. Not quite as good as my 2015 WR but not half bad. It's actually a bit tragic when you think there's nearly 15 years between the KTM and my mates yam!

Grant, forks have been serviced this year, not that there's much in there to service lol. Are the ORVS kits much good, the benchmark being a 20 year old WR! I get the impression they just turn them into something similar to the OC forks I had on my 2012 KTM, which again weren't the best tbf. I don't mind spending a reasonable amount of money if it sorts them, I kind of just associate anything *********** as a bit naff lol. Had crossed my mind putting a set of WR forks on it but no idea what bits are compatible etc.

I did spot a set of ohlins forks on ebay, bit overkill though maybe!
 
#4 ·
Grant, does the ORVS kit turn them into proper OC forks? If so is there a reasonably simple way of doing the same using older 2016 base valves etc? I’m guessing at this route being cheaper than 6500s.

Another option is sniff out a set of CC or OC forks off an older model. Both can be really good.

I’ve a set of excellent condition black cone valves owned by me from new but I’m not ready to sell unless the price is very right….
 
#7 ·
pretty much yeh. you replace the base valve with an adjustable one like the older forks and replace the mid valve making the top adjuster a rebound adjuster on both sides, unlike the split oem design.
it can be done with OEM parts, this is the way TBR suspension & eurotek do it. But the k-tech kit looks like a nicer quality kit side by side.
ORVS is good but its more labour intensive than 6500s to install which brings the price difference closer when you factor in parts+installation costs.
 
#6 ·
A lot!🤣

Probably around half the price of new current stuff. This is just in case “a friend” decides to get another pumpkin. I doubt that will happen as things are not improving but I do love how the CV work. They are mega once set up for you.
 
#10 ·
My two penneth worth. I fitted DS Sphere in my ‘19 TPI after riding Pindie’s. The difference is night and day, I move them from bike to bike. I rode my mates ‘19 FE with ORVS and they felt like a standard fork, noticeably harsher than my DS and not pleasant to ride. Now his may not be set up properly but I will say spend as much as you can afford on suspension as it is probably the most important component of a dirt bike. Another option is a well set up set of CC, which I also have as a spare. I’ve yet to try 6500’s.
I believe you can fit KYB to KTM too?.
 
#15 ·
For internal cartridges Sphere have to be right up there. There are also Ohlins and KYB fitments.

OVRS are very good but you still have an OC fork (arguably the better extreme or woods fork). You can also use genuine WP parts to turn Xplor into a very good and adjustable fork- like the 2016 OC forks.

A set of CC forks is an option. Can be made amazing and you’ll have the whole forks not just internals. Big or small axle doesn’t matter as only different spacers and geometry tweaks are needed to make them work.

Cone valves are an option but they won’t be cheap. Never buy cheap cone valves! They are probably going to be scrap. CV need to be tip top to be good.
 
#16 ·
I sent my Husky suspension to RSS (Recomended by Lee Walters) and it transformed the forks, probably nowhere near what 6500 kit would do - but for the money (and my trail riding use) it was great.

From their Website:

"And new for 2017 onwards !our exc kit, which compromises of a revalve to suit rider discipline, weight and ability, a bladder conversion for shock performance and consistency, and a fork adjuster kit, which adds the ability to adjust low speed compression…. it’s a great setup"

This is what I had done a few years ago, about £500 (may be more now - isn't everything!) and the forks feel a lot nicer, considering a service would probably cost a couple of hundred I was pretty happy.

 
#17 ·
That sounds quite interesting, sounds a bit like the ktech kit, just turn them into conventional oc forks I presume. Have you used them at speed over rutted bumpy ground? Bit hard to gauge how well stuff is working green laning I find. Definitely a better number price wise though!
 
#19 ·
Your idea of at speed and mine are probably very different.

Occasionally do an enduro fun day on a very bumpy / rutted track and it is way better - i can tell as before my arms were fucked before I completed a lap, now I can do a lap with way less fatigue

Give them a call, I am sure they will have more of an idea and happy to upsell if you want 😊
 
#20 ·
Without knowing your speed/pace, I’d say OC will be fine. However, if you ride fast trails and might have the potential to smash into a washed out trail/ditch then CC can offer a theoretical better coping strategy but….one offs seem fine with decent OC. It’s repetitive big hits like braking bumps where they shine if you go fast.
 
#21 ·
I guess speed wise, your average clubman rider really. I do have a habit of trying to ride faster than my ability allows where I've found decent suspension is a god send when you get it wrong lol. I certainly found the suspension was holding me back Sunday though, I wanted to ride faster but it was just dangerous. How does the 6500 kit compare to modern kayaba stuff out of interest? The more I think about it the more I think that's the way to go. I've seen them from a couple of suppliers, they sort of suggest they come valved to suit you individually as such, is this the case? Waiting for an email back from AMS at the moment.
 
#22 ·
6500s would be an investment as you can transfer them from one Ktm to the next. You benefit from using the stock tubes so no odd geometry. They will still be worth a lot of money when you are done with them. Simple service (ish) as all spanner work. No bladder etc. external pre load like with CV forks.

I’ve not tried or seen them in the flesh but on paper they seem the best WP offer and a lot less than CV. Getting the right set up will be key.