AER Fork Rebuild

Want to learn how to service you KTM AER Forks? Here is a good video to show you how to do it with some normal tools. Below are links to all the stuff I used in the video.
Seals: amzn.to/2TwswLr
Driver: amzn.to/2uLkVjJ
Fork cap wrench: amzn.to/2TBirNc
Inner chamber wrench: amzn.to/32Jkz9N
Fork Oil: amzn.to/3cvaIcv
Thanks for watching guys, now go ride your DIRTBIKES!!!
#gospeloftwowheels #dirtbikes #AER #KTM

[@bryankimsey8167]

Great video!!! Getting ready to do the forks on my KTM 150sx and these are the tips and tricks I need to know!

[@highlandcycles]

Awesome

[@13CDallas]

Great Video dude! SOLID!

[@highlandcycles]

Thanks

[@Andy-co6pn]

Great vid ! just a bit of info, A kyb sss fork is a copy of the showa tc fork. Thats why until recently KYB couldn't put holes in their plastic free pistons because it infringed the Showa copyright.

[@highlandcycles]

Ahhh. That’s interesting

[@wfo_racer]

Morgan I'll be sending my 2023 AER forks to you. You got the gift buddy.

[@highlandcycles]

Thanks man. We can make them really good

[@davidbeauvais1364]

@@highlandcycles can I just send you the damper side insert for a revalve? I’ve changed seals and done rebuilds many times I just don’t wanna mess with shims by myself.

[@highlandcycles]

@@davidbeauvais1364 Yes we can do that

[@Norcal2stroke]

Thanks for all the great videos super helpful! I cannot find the red Scotch Brite video? Thanks again...

[@highlandcycles]

matt tuell I am pretty sure it’s in this one kzbin.info/www/bejne/eZWuqaGMnNuke5Y

[@EC-xo4ti]

Excellent AER 48 assembly/ disassembly video. Any need to change quad ring or other seals/ guides?

[@highlandcycles]

Not on this set.

[@stephendavis7707]

i had a handling issue on my 21 husky 450 so i changed all the seals etc on the forks but the inner air chamber seems to be locking i can only put 2bar of air into it befor it locks out and does not compress at all ? is that the inner seals ? or even lack of grease .. The bike is new to me so i have no previous history of when or if the suspension has been service but i followed your instructions and everything went good ..

[@goranmediamax543]

Hello,great video,can you help me with harsh suspension on ktm 250 sxf 2016(aer 48 fork),I’ve tried with exact positioning of both forks and same result,after driving,I’m dead,my hands hardly feel 😁,but I’m beginner,I thought I’m out of shape for this kind of sport,but when I looked on my friends bike,my suspension is much harder,so what can be be the issue?

[@farmer3242]

My 2020 450xcf has done 19 hours and the aer forks are sagging down quite alot, i checked the pressure and it still had 140 psi so it hadnt leaked out. What could the problem be? I lv just finished servicing my 2019 250xc forks by watching this video. The hardest bit was heating and breaking loose that internal nut, i got it done without damaging anything, i didnt replace fork seals because they wernt leaking, i just greased the valve and replaced all the oil. Thanks heaps man youre a legend!

[@highlandcycles]

They can leak air onto the wrong side of the piston in the air side and cause them to do that. It’s not much so it won’t look like they have dropped pressure. You have to disassemble like you did on the 250

[@farmer3242]

@@highlandcycles thanks, so which seal will be leaking the air? Is it the o-ring on the valving that you slapped all the grease on? I noticed you didnt replace that o-ring, just greased it up. So which o-ring do you think i need to replace? Thanks man👍

[@highlandcycles]

@@farmer3242 It is the big seal for the air piston

[@farmer3242]

​@@highlandcyclesi found a post on internet about sagging aer forks and they said to hold the front wheel down to the ground by having someone sit on wheel or tie wheel down somehow and pump forks up and down and pull them up to full extension and the air will escape back into correct chamber and fix the forks. My forks were stuck down at about half stroke. I did this and it worked perfectly. I so glad i didnt have to take it all apart. I hadnt ridden bike for about 3-4 months and in the last 2 weeks i noticed they had sagged. Great tip for everyone with aer forks.

[@highlandcycles]

@@farmer3242 I have heard of that too. I just like taking them apart to inspect everything and lube it all up because they shouldn’t leak like that. Something else isn’t perfect if that’s happening

[@chrisstagg4308]

Hey Morgan! Would the internals of the WP AER 43 fork that are on a 2019 KTM 85 be the same as this just smaller? I’m about to do the seals on my sons. If not, have a link that’s good to follow?

[@highlandcycles]

It’s basically the same. There are differences but you should be good.

[@throttlebuff]

Dude, I'm watching you pump the oil out of dampening side and its effortless. Mins is binding up in a couple of spots and it is not fluid feeling. When i reassembld it the fork doesn't fully extend. So it is shorter. I rebuilt the forks because i thought my aer was sticking however i think this may be the problem instead. Wondering about a full disassemble to check the seal inside. Any advice? Do i heat the end like the AER one?

[@highlandcycles]

Yes. Heat it up. Have all the orings to rebuild it on hand too

[@blarpieman]

Did you find the need to measure in CC how much oil goes into the cartridge or did you just over fill and pump the excess?

[@highlandcycles]

Motoman744 over fill and bleed the excess

[@igortbp]

Hello, I'm looking to change the seals on my SX150, but I'm unsure about the type of grease I should use on the air cylinder, what would you recommend to prevent wear and expansion of the air cartridge seal?

[@highlandcycles]

The white lithium stuff that KTM uses is good.

[@enduro-parts-aus]

Good video you do it so much quicker then me 😂 , what grease did you use on the air forks

[@highlandcycles]

I use Motorex

[@blarpieman]

Once you heat the cartridges with a torch do you replace the blue and purple seals have you had a failure after doing that if you don't replace. I am interested to know how those seals are affected by the torch. Great video's!!!! Great channel.

[@highlandcycles]

You have to be super careful on that. I’ve never had a failure. I inspect them closely and if they look questionable at all, I replace them.

[@blarpieman]

@@highlandcycles How many hours do you like to replace those seals and the oil side cartridge seal as well? thanks

[@nomdeguerre13]

Hey Morgan, is the loctite really necessary? Seems as though the grease, even residual would interfere? Put an Innteck Seal Glide kit in the fork today and did not use any, but now I am second guessing that choice.

[@highlandcycles]

It should be fine.

[@nomdeguerre13]

@@highlandcycles thanks, been up since 2330 last night, so missed it and over thought it a bunch. Have a good weekend.

[@cooliomilkman]

I have a pair of AER48 forks that are 2021 I believe. They have a clicking sound in the air chamber side when I compress and let go of the fork leg. Is this normal? Or should it only make sounds when it’s fully extended at the top?

[@MechShark]

Definitely not normal. How many hours? It's due for an inner cartridge rebuild if there's a ton of pressure coming out of the bleed bolt up top after it sits for a few days.

[@nickschoenly742]

So on the oil side. Do you need to add oil to the leg also? You said 220cc but it sounds like thats only for the spring side. I feel like I'm missing something. As always thanks for the great videos!!

[@highlandcycles]

Sorry. Yes you need to add to the outside chamber on the right side also.

[@highlandcycles]

And it’s 220 cc in both outside chambers

[@nickschoenly742]

@@highlandcycles awesome thank you. Love your videos! Whenever one of your videos comes up whe looking for tech info I'm always sure to watch it so keep it up!

[@highlandcycles]

Thanks so much

[@ericbulic8589]

Hey Morgan, I have the 2020 wp AER forks and man they are stiff up top. Any recommendations to making them a little more plush over rocks/roots? I am riding on the East coast and have been all over the place with the psi and clickers. Thanks, love the content

[@highlandcycles]

Probably the best and easiest thing is to buy the 2021 air spring. It has a different balance chamber and really helps with that harshness. The next thing would be to have us install the WP cone valve adaptation kit and valve it for you but that isn’t cheap.

[@ericbulic8589]

@@highlandcycles hell ya! Thanks for rec. You rock. I’ve binged like 10 hours of your videos lol. Nice family and cool business

[@highlandcycles]

@@ericbulic8589 thanks so much

[@ericbulic8589]

@@highlandcycles no problem, and do you mean the 21’ ktm air spring? Or the k-tech insert? Any part numbers for it? Thanks again.

[@highlandcycles]

@@ericbulic8589 KTM insert. I don’t have them in front of me but it’s the right side chamber on all the 21 and up AER forks. It’s still air but way better.

[@bryanwittersheim7941]

Do you grease the compression side too? Thank you

[@bryanwittersheim7941]

Also sorry forgot to add, great video. New subscriber

[@highlandcycles]

The other fork is like a normal fork just no spring. It’s all oiled up.

[@the229project4]

What type of grease do you use for the air cartridge?

[@highlandcycles]

I use the high pressure Motorex stuff.

[@osvaldodavia8844]

@@highlandcycles hello, can you tell me what kind of fat it is ??

[@zorro324]

how much oil did you put in the right fork?

[@highlandcycles]

Just a few CC’s. Maybe 5-10

[@DarkenedRez]

What does it mean if my aer forks aren’t rebounding all the way up?

[@highlandcycles]

Could be that the air spring needs to be serviced. They need grease

[@highlandcycles]

Or you could have a leak in the seal that keeps the air in the correct side of the chamber

[@davidelarosa5809]

which grease should be used ?

[@throttlebuff]

i saw some dude on RMATV using race tech fork grease