Returning 4CS Forks back to OEM

[neevo]

I have a new bike on the way which is very exciting. My current bike (Husky TE300 2015) is fitted with Dal Soggio Sphere's and has the upper tubes Kashima coated. Naturally I want to keep both of these and so I plan on doing a swap of the best parts between both bikes.

I was going to get the shop who put the Dal Soggios in but a mate of mine warned that its not going to be cheap and looks like its way more than I budgeted. I can see why given the Dal Soggios are fitted by taking the axle lugs off the lower legs.

So my plan is to try and do a bunch of the work myself, return the old 4CS suspension back to stock, keep the best parts for my new bikes front end and hopefully keep my swap over budget to (hopefully) buy some coated lowers, plus springs and a revalve on the shock.

I am clear on how to strip the lowers to get the bottoming device out for the Dal Soggios, but I have not had much experience with the 4CS, only WP open chamber forks.

Is there anything I need to put back in between the lower legs and axle lugs for the 4CS? I dont see anything in the parts I have on the bench but I wanted to triple check before I start stripping the legs and machining tools for the job.

[Craigy]

Probably best to give Terry a call at Shock Treatment. He will know all the details.

[neevo]

I’m out there this week picking up my mates suspension. I’ll ask them for best approach. They’ll get my money either way as they set me up with the Dal Soggios.

Was just trying to see if I could save the swap over money for coated lowers.

[KtmJono_777]

I would just watch a few videos on YouTube of people servicing / rebuilding 4CS forks. You should be able to see most of the internals and how they fit together.

[380EXCQLD]

What's it cost to get new Sphere's & Kashima into your new forks?

[neevo]

I would just watch a few videos on YouTube of people servicing / rebuilding 4CS forks. You should be able to see most of the internals and how they fit together.

I did that and it looked very simple and didn’t look like anything was between the foot and lower tube. But it’s hard to guarantee that without finding a parts diagram.

[neevo]

What's it cost to get new Sphere's & Kashima into your new forks?

I’ll have to double check with the boys at Shock Treatment. Maybe my mate was scaring me unnecessarily. But the thought of doing some manual labour myself and reinvesting that money in to some DLC lowers is very tempting.

Id planned on about 1K to get the shock done and move the Dals, but haven’t spoken to Shock Treatment yet. I’ll have a chat with them and see what they say.

[tmac450]

What is the new bike? I had a similar situation in 2020. Had custom forks and shocks on my 2018 350 and bought a 2020 350. I just did a complete fork and shock swap. Had the added benefit of selling my with brand new suspension and got to keep my good stuff.

[neevo]

What is the new bike? I had a similar situation in 2020. Had custom forks and shocks on my 2018 350 and bought a 2020 350. I just did a complete fork and shock swap. Had the added benefit of selling my with brand new suspension and got to keep my good stuff.

I’m going from a 2015 Husky TE300 to a 2023 KTM 350 EXC-F

Exact same plan. Put new outers on Husky and keep Kashima coated ones. Put internals back in Husky lower legs and current springs (so front and rear are matched for new owner).

Box of bits to take to Shock Treatment to put Dal Soggios back in, hopefully with coated lowers.

The KTM uses a new smaller front axle so I have to swap the lowers unfortunately. Otherwise I’d just do a straight front end swap.

[neevo]

Phase 1 complete. I had some spare time in the garage so thought bugger it, might as well crack out the tools.

I have the forks stripped down apart from separating the lower legs from the axle lugs. But I’m having a break and will get back to that later in the week. Aiming to have all the legs broken down, get the new bike and do the transfer with the various components.

It will also give me a chance to chat to the boys at Shock Treatment on Thursday and see what options I have to do the swap and see if getting some coated lowers is in the budget/plan.

The good news is that my coated uppers are in immaculate condition. Perfect inside and out. Not even a single chip, which I’m very happy about (they were serviced about 5 rides back).

IMG_0157.jpeg

[KtmJono_777]

Looking good!

[axel]

The KTM uses a new smaller front axle so I have to swap the lowers unfortunately. Otherwise Id just do a straight front end swap.

You still can do a straight swap.
Keep the lower axle clamps.
Keep the larger axle.
Swap the wheel spacers over to your newer rims.

I have done as above recently. I'm using my '08 KTM rims on my '23 GG. Just s spacer swap.

[neevo]

I didn’t know that. Hmmmm. Might save me pulling all the lugs off.

[Craigy]

I didn’t know that. Hmmmm. Might save me pulling all the lugs off.

Just be aware that you will change the steering geometry slightly.

[neevo]

I just went ahead and pulled the lugs off. Made a custom tool on the lathe:

IMG_0178.jpeg

A bit of heat on the axle lugs and they came right off.

IMG_0177.jpeg