How To Rebuild WP Xplor Forks

[@Gooooch]

Even though I don't own half the stuff you guys work on or do repair videos on I still watch because they are so well done and informative.

[@rmatvmc]

thanks!

[@gioge2666]

Air level????

[@brucedecker8940]

What I great video. So precise and well done. A couple of differences on the WP Xplor 48 from my 21 KTM 890 Adventure R: 1) My bottom bolt is a 7mm allen, not a 17mm allen 2) If changing springs (I was going to a stiffer spring), the inside diameter of the coil was smaller because of the way the top of the coil was welded. I had to grind the id of the coil to allow the top cap's puck to fit inside. I hope exposed bare metal of the coil will not set off a corrosion reaction. When trying to 'move the plastic guide flute downward to allow some gap, then bring up the bolt, I could not get either of mine to budge. 3) Would be nice to use an oil level measurement rather than rely of 630ml +/- 5m but It's hard to find that oil level spec anywhere so I guess just measure carefully is the best option.

[@rlmartin1988]

Well done video Justin. One item of note though is that when you "loosen" or back out the rebound adjuster prior to disassembly, the internal pin retracts into the fork cap. However, I noticed that for the compression side, the opposite happens. With that, I would offer that the compression adjuster needs to be "tightened" or turned in prior to dissassembly or assembly. Thanks for the effort on these instructional videos.

[@ranvirsinghnetam8584]

will applying grease to the seals attarct dirt on the inner tube for a few days

[@rlmartin1988]

@@ranvirsinghnetam8584 Not a fan of using grease myself as will attract and hold dirt/grit. Prefer quick wipe down after or before riding and light oil application to remove dried grit in reducing risk of damaged seal lip.

[@TheElectrovideo]

Thanks for posting this video. I had an issue with my 2022 TE300i that really bummed me out. The rebound was not working at all. The rebound clicker would just spin turning clockwise. Pretty upsetting for a newer bike. After learning how to disassemble from watching this video and buying the right tools I found to my amazement that the rebound rod had become unthreaded and was the issue. I put it all back together and all is well. Great instructions and detail. Thanks!

[@rmatvmc]

That's disappointing you had that issue. Glad this video helped out!

[@mattbillenstein]

Thanks for the video - scratched the hell out of my fork lower - bought the parts from you guys and fixed her up!

[@Wanderlustmaps]

The way you explain it gives us confidence that even we can do it. Thank you

[@chinski1]

Just completed mine from this tutorial , thankyou , it was perfect 👌

[@ilcatto217]

Great video, very clean and precise. Grazie!

[@HeAdChEeSe1983]

Great video! Between this and my sevice manual I think I will tackle this while there is snow on the ground. Of course I'll buy my parts from you.

[@rmatvmc]

Good luck! Thank you for watching!

[@jeffestrada6857]

Your very good Dustin. Very clear voice and instructions 👍👍 Thank you 😊

[@lemoinexavier]

Thank you soo much! Greatings from Belgium. 😉 Great channel btw.

[@ranvirsinghnetam8584]

will applying grease to the seals attarct dirt on the inner tube for a few days

[@gabrielfalcao8892]

Muito obrigado,seu vídeo me ajudou muito aqui no Brasil 🇧🇷

[@rmatvmc]

De nada! Estamos felizes que o video ti ajudou!

[@yuricoyuri79]

Отличное подробное руководство, хорошая работа!

[@christianelliott3667]

My bike is a 2018 and has the xplor forks but the compression and rebound caps are different is it still the same break down?

[@TeamStruggleBunny]

Would like to see the install of upgrade kits on this fork or a video on valving.

[@MarkSpencerAZ]

Considering that one fork has rebound adjustment and the other compression, are the forks still identical in their inside components?

[@seazv]

Hi buddy what’s happen if you change the spring in wp forks that only have spring in one leg? The ktm 1290 Super adventure R 2021+ have preload adjustment in both legs but only one visible spring in one leg, I it is 6.5nm I’m looking to put 7.0nm, but I don’t know if that will cause problem as the other leg don’t have spring. Thanks

[@leftypicker867]

Brilliant video @rockymountainatv !! Are the 2022 xplor the same?

[@Glasscock14]

Are these on the 2017 KTM 1090 Adv R?

[@sercanaktas93]

hello, are we doing the same technique in 2015 sixdays engines?

[@JWA_F]

I havent found a video regarding the WP 48mm USD forks used on the 2016 1190r. I assume the break free of the preload cap in order to remove the spring afterwards is similar?

[@justinsmith7808]

Did you find out, that’s what I’m looking at doing rebuild on

[@AlexKost-tq6bj]

How do you torque the preload adjuster to 18 ft-lb with that wrench?? Looks like you just tightened it by hand, is there a tool (socket) that would allow an actual torque wrench to be used?

[@hans-pettereikedalen423]

Good video! My fork cap comes loose and is almost coming of by hand, but then gets stuck on the threads. I have not pushed further. It was like that on both forks. Any tips?

[@davidtompkins1234]

My 2017 ktm 1290 SAR has Xplor forks will they be the same and will I need any different tools?

[@andrewtempelman]

did you find the answer to this question?

[@johnnyborders628]

I have a 2022 gas gas ec300. I can't get the inner chamber to fill up with oil. On compression side recommend 615 cc's the shaft is cavitating even when I turn it upside down and fill it from the bottom?

[@jayclose1945]

I'm having the same issue, I have no dampening, did you get you issue fixed?

[@alexguiver815]

Thanks for an excellent how-to vid! I have the 2020 version (stock on a KTM 250 EXC TPI Six Days) which look very similar to these. Manuals are available on the WP website but to download the correct one I need the product ID, is this easy to find on the fork? Thanks again

[@ricardocuetara1]

Great video. Thank you!

[@NirHason]

Tnx for the video! If I have the regular XPLOR without the pre-load adjuster on the top, how do I open the cap?

[@ericahearn9604]

Just use the fork cap wrench...50mm

[@NirHason]

Tnx

[@Youggen]

Im going to do this job on the bike, and want to thank you guys for the best how to videos out there. I just bought my bike used and found the compression adjuster not stopping when im turning it clockwise, the stop is broke. Do i need to buy a new complete fork cap or just the adjuster knob ?

[@mbrick]

Your comment was a while ago but replying for others as well. I had this same issue. The small brass pin inside of the cap has threaded out and disengaged from the knob on top. It only happens on the compression side because it is reverse threaded from the rebound side so it unthreads when removing the cap. You can lightly thread the brass pin on the under side of the cap back in by turning it left (not right). Once you feel it stop, rotate the adjuster knob clockwise and it should engage and thread the brass pin down into the cap and then bottom out. This NEEDS to be corrected before reinstalling the cap or the compression will not be adjustable.

[@specializedbighitfsr]

Looks like the manual calls for 4w oil for the xplor 48. Much difference in compression and rebound damping with the maxima 5w racing fork fluid? Thanks.

[@pkerttu]

No, not at all

[@plamenkovachev238]

Can you make left fork?

[@SwormCycles]

My '17 XC-W 300 does not have the spring preload adjuster. What year are the forks you are working on and is this process the same for the forks with no preload adjuster?

[@FATBIKEMIKE]

Just re-sprung my forks noticed the compression dampening rod has compression for about 2 inches and then it just falls into the fork I’ve cycled it so many times it only has compression on the first two and the last 2 inches of the stroke I can’t seem to figure out what’s going on it’s like there’s zero compression in the middle

[@kidgerman08]

Mine does this also? Plus no spacers in either tube?

[@דורסבדיה-ט2כ]

When you do a service to suspension, you always need to switch also the bushings?

[@gregmossed]

For anyone else - no. That's why he demonstrates how to check them for wear. If the Teflon surfaces are intact, leave em.

[@shimaze5479]

Is ‎FCW-06 the part number for the Tusk Explorer preload cap wrench? Amazon says it is NO longer available and the search function DOES NOT work on your website. Is this tool still available or has it been discontinued?

[@rmatvmc]

Yes, that's the correct part number. We are just waiting for more stock before they are back on the website.

[@MarkSpencerAZ]

Tried to tell a suspension shop that just worked on my bike to use the correct tool for loosening the rod from the fork cap and they insisted, not necessary, we always use the fork cap wrench, aye! Seems everything is working OK, but these are reasons why I usually do all my own work. See explanation at 4:00 into video of why you should use the tool shown at 2:58 in the video.

[@treagan2666]

There are several comments regarding plastic spacers. 2 came out of my 2021 XPlor 48 compression fork. The parts schematic shows only 1 to be inserted on top of spring beneath the preload adjuster. The video shows only 1 inserted under the spring before inserting the spring. I guess no big deal if there is 1 on top and 1 on bottom, yes or no? Anyone? Anyone? Anyone?

[@ReedBM]

Are there fork spring spacers on both sides? I had a spacer on the rebound side, but no spacer on the compression side.

[@mmill2179]

What is the 48mm socket for?

[@BlackBoneAMX]

Thanks, an awesome video. How can I use the Tusk oil level tool to add or subtract oil from my 2019 Husqvarna Explorer 48's?

[@BlackBoneAMX]

For the question above, add, with forks installed in the field through the bleed hole?

[@motoktips3024]

I'd be glad if you rebuild a 1190 adventure electronic fork some day soon :-)

[@richard78717]

What are them shocks off of? They look like the same as my 2017 ktm 250sx

[@rmatvmc]

2017 TX300.

[@Cactus73]

TE300...TX has AER forks

[@rmatvmc]

Correct. TE

[@waris6755]

What forks does Tx 125 2017 use

[@ChrisKAloha]

FYI one fork may have the plastic spacer under the spring and the other may not. I see on the internet this is normal.

[@awesomojack]

What do you do if you don't have the spring preload adjuster? My xplor48 forks just have the red dial and not the big silver adjuster. Do just hold the lock nut under the fork cap and loosen the 48mm fork cap putting pressure on the internal fork cap parts?

[@mbrick]

Yes. Except in this case the cap is solid, so there are no internal parts to risk damaging.

[@martincilic]

Hello, I have huge problem. I do everything same as you. And I am holding hexagon under spring with 24 wrench and unscrewing it holding it for adjuster but when it comes up to the end of thred it stops. I cant disassamble it.

[@alexs8312]

i'm just gonna hire a guy when i need this done.

[@OHrider22]

QUESTION: I just reassembled my forks and I noticed the adjusting rod that sits within the piston rod on the rebound fork kind of seats and then has some spring to it when you press it up and down, but the one on the compression fork just seats and then does not move at all when you press on it. Is this correct? Or is something messed up? Thanks!

[@ptr82]

I have it the same on mine

[@senibesitempa4176]

how much oil in 1 tube

[@marcjones1967]

How can you check the torque settings on the cap when your using the special tools ?

[@RedLightning]

With some of those special tools, there is a little square near the head of the wrenches that fits a 3/8" socket, so you could use a torque wrench. Or just feel it out

[@eugenelane3291]

Go by feel. 15- 30lbs Snug is snug..,

[@niccolocortese4953]

Is it possible on my forks there was 1 teflon spacer in one fork and no spacer in the other fork?

[@jayclose1945]

I have the same issue, I thought I lost it

[@mimrans41]

Hi The eu manual says 21.47 oz fork oil What is the right size?

[@robwal3665]

Hi my rebound adjuster keeps turning clockwise, if I back it out it will hit a stop but no stop when turned in. Is this likely to be a minor fix or something more expensive ? 17 , 350 exc

[@JONBOYLEMON]

Take fork cap off and look underneath for a little brass piece that has come unthreaded. It will either tighten by going clockwise or counter clockwise, cant remeber which side is which thread.... But get that brass piece threaded in again and bottom it out and then run clickers and see if the brass piece moves in sync with clickers.

[@gioge2666]

Oil level????

[@ariag.a3620]

The spacer between the spring and the thing under it was missing in my fork. I bought mine brand new, and it is a 2021 KTM 350 EXC-F. Does anyone know if that is normal?

[@kylerobson1103]

Why does the 50mm wrench have a notch in it?

[@michaelsteven1090]

I don't have pre-adjusters..Is it the same procedure?

[@rmatvmc]

correct! thank you!

[@robertsilvarprmotoracing9083]

How much oil in that suspension???

[@robertsilvarprmotoracing9083]

How much suspension oil?????

[@coarsegoldkid]

My Xplor forks have been reworked to be 2 inches shorter than stock. Does that effect the amount of oil needed? Thanks in advance of your reply.

[@randerson7761]

yes

[@robertsilvarprmotoracing9083]

How much suspesion oil??

[@gioge2666]

Help me ....my Wp xplore 2020 of Hqv fe: air level 130cm= 1,4 lt, 700ml for fork 😳😳....why? Hight level and very to mutch oil🙈

[@markozer0]

thanks for the video...but what about the oil level?! I think you can show how measure to have correct level, many thanks

[@556Bushmaster556]

The video shows the Red fork ( rebound). When I bleed the other fork ( white, compression). The dampening rod never seems to start dampening. If I pull the rod all the way up, and let go it will very quickly fall back down. Is this normal for the compression side??

[@rafy600]

I just did mine last night because my suspension collapsed maybe 2 inches after a race this sunday and I also have the same concern. Can anyone answer and let us know if this is normal. The bike is a 300 tpi 6days

[@rafy600]

Also mine don't have that white plastic spacer that goes before the sprig

[@ptr82]

I have just did a rebuild to my fork legs and have the same situation as you guys are desribing. No spacer in the compression leg and no damping either. Not sure about the spacer, but no damping thing is fine for me

[@kimojon9665]

@@ptr82 Anyone reading this now, there is no spacer (teflon washer) on compression side but there is on the damper side. Also on one side when you are deleting air in the oil system, there will. not be any drag on one side but there will on the other - completely normal. Rocky Mountain did an amazing Job on this video but wish they would have explained these items as a lot of people are confused. In addition, on these particular forks, you do NOT need to set ring oil position. Just install the correct amount of oil and then delete the air appropriately

[@johndundas1348]

Good tutorial, but what about the fork oil height adjustment prior to installing the spacer, spring, damper rod and cap? Minor omission, but you may want to revise the video and add that in.

[@randerson7761]

He gives the fork oil volume

[@gioge2666]

Hi, halp me, quantity for fork 615ml? And air level???

[@fiddler181-twowheelin]

No Air in this fork! This is WP Xplor 48 not AER

[@gioge2666]

@@fiddler181-twowheelin level air.....110mm

[@SANDS78]

No need to check fork oil level height?

[@conner456]

"torque to 18.4 foot lbs" then hand wrenches it haha

[@V4Amore]

Dampening makes you wet. Damping makes you fast. ;-)

[@CypressRacing]

You said "rod" and "shaft" over 30 times!

[@rmatvmc]

Go take a cold shower!

[@spoonking8750]

No.

[@sercanaktas93]

How many grams of oil is put for 1 shock absorber.

[@robertsilvarprmotoracing9083]

How much oil in that suspension????

[@RedLightning]

Check your manual, but in my fathers 2017 TE 150, its 610ml. Although in my 2019 TE 150, its more than that, so check your manual

[@robertsilvarprmotoracing9083]

How much oil in that suspension????

[@robertsilvarprmotoracing9083]

How much oil in that suspension?????

[@rmatvmc]

It will vary depending on your bike but we put 20.62 fl oz (609.8 ml) in each of these forks.

[@robertsilvarprmotoracing9083]

@@rmatvmc obrigado pela atenção.🤙🤙🤙🤙

[@robertsilvarprmotoracing9083]

@@rmatvmc how much level mm ???