2008 chrome fork tubes help

fe600racer · Feb 6, 2010

I am replacing the fork tubes on my 2008 Berg. I note one of the replacement tubes does not have the long indent that starts a few cm's from the top of the tube like the old one does. When the tube is seperated from the outer tube you can see the top of the tube has three big holes in it and then the thickness is reduced for about 14 cm and then the thickness returns and that is the thickness you can see when the forks are assembled. One of the replacement tubes has the same thickness right through except where the Du Bush goes. What does this machined indent do, why might one of the replacement tubes not have it.

would appreciated help on this as I would hate to re-assemble with this tube only to find a problem later.

bushmechanic · Feb 6, 2010

can we see a pic ? :?

fe600racer · Feb 7, 2010

struggled a bit to attach and get a clear picture, but hopefully you can see. The old tube with the 1mm deep and 15 cm long indent is the one closer to the white paper, the new tube without the indent is below. In the parts manual you can see the indent marked as a rings on the drawing. the indent looks machined and must be for a purpose???

bushmechanic · Feb 7, 2010

ah that thing

I think its to allow a reasonable volume of oil to be trapped between the 2 bushes and allow the lower one better lubrication or it may be just a lightening thing, the leg without the indent will be stronger.

if it worries you that the new leg doesn't have it you could search the doc or KTMtalk for the "2 holes mod" which is something ohlins came up with in the stone age. that should get a bit more oil to the lowe bush or it may not..

in any case I can't see how the new leg will work any different to the old one in practice

fe600racer · Feb 8, 2010

thanks Bushie, apparently that change came in the 2008 year and without the ident was 2007 and prior. I think you may be right about oiling the lower bush. I would prefer the indent tube as it must have been done for a good reason? I will check out the ktm talk, but I wonder if other Berg owners have a view particularly the earlier model: worn bushes or other problems or input to what the indent does?

fe600racer · Feb 8, 2010

Bushie, I checked out ktm talk and note the straight tube design has an extra bush and an aluminuim spacer that looks to be the same length as the indent on the 08 forks. It seems that binding and spiking has been the problem and the 08 fork has removed a bush, the aluminium spacer and replaced with indent? If I am right I cannot just use the straight tube without the indent? Do you have an 07 manual that shows whether the 07 fork has this extra bush and aluminuim tube as I only have the 08 parts book?

bushmechanic · Feb 8, 2010

plenty forks have the straight through diam with 2 bushes

put it together on the bench and check for smooth action, if you can get the other one instead its probably better so both legs flex the same but I reckon it'l be fine.

I have an 06 apart it has the indent, i think its around 03-04 that has the 3 bush

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