What is really going on at KTM?

kopfjaeger
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10/17/2025 5:42pm
aees wrote:
All shocks fade. Even at Honda they started of stiffer with Sexton's clicker settings to compensate for it.WP shocks fade, I can feel it myself. After...

All shocks fade. Even at Honda they started of stiffer with Sexton's clicker settings to compensate for it.

WP shocks fade, I can feel it myself. After first session is done and you go back out for second if it's reasonably warm outside, it's 0.25-0.5 turn on HSC and 2-3 clicks on low speed to get bike balanced.

Try to run that setting when bike is completely cooled of and it's unbalanced, rear end high and deflecting.

 

PNWMXer wrote:
Just out of curiosity, are you running the stock floating piston or a bladder conversion? I am still on the former, and can definitely feel a difference...

Just out of curiosity, are you running the stock floating piston or a bladder conversion? 

I am still on the former, and can definitely feel a difference once the shock gets hot (which seems to happen quickly). Feels almost like a rear flat at times once it’s hot. Wondering if a bladder conversion would help.

I have a bladder conversion on my bike and don't notice any fade, but have ridden stock KTMs and do notice the it feels worse when...

I have a bladder conversion on my bike and don't notice any fade, but have ridden stock KTMs and do notice the it feels worse when it gets hot which I agree seems to happen more quickly than you'd expect. Even on trails the shock just seems to feel sticky and stiff once it gets warm after 15-20 minutes of hard riding. 

My son rode a bike 5 years or so ago w/the bladder kit. And has had one ever since. He can feel the difference even in sweepers. With the piston it will stick and suddenly go or whatever making a simple sweeper sketchy at his speed. The bladder fixes that. KTM rears have always been sensitive to overheating especially with new pads. You have to adjust the lever some.

Bearuno
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10/17/2025 9:26pm Edited Date/Time 10/17/2025 11:31pm

20251018 151425As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.

Heck, I had a bunch of older shocks cluttering up the under bench space, and, the old beastie had a bit of a tendency towards shock fade when it was still a Linkaged bike, in some of our 4hour GNCC type races, especially at a Sand Whoop infested course.

So, grab a resi, from a 83 Floater, remove and weld up the primitive compression adjuster, make a new end cap for the shock resi, the 02 bladder and cap fitting in the 83 resi, and you've got a Hell of a lot more oil capacity. 

Shock fade : Gone. Oil would come out the same colour as it went in, whereas, std, it would come out thoroughly cooked.

I've been meaning to put one on the Ohlins TTX, but, well, I really don't come remotely close to hammering nowadays - I Plod Along, stoically. 😉

14
Sandusky26
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10/18/2025 4:09am
PRM31 wrote:

Why don’t Euro KTMs have the same problem?

3strokemx wrote:

They tracks arent as rough in the GP's, the shock doesnt get as hot. 😮

aees wrote:
Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get...

Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get to MXGP roughness.

Not really fair to compare the sand tracks which everyone knows gets rougher. What about all the harder pack tracks?

Gravel
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10/18/2025 7:47am Edited Date/Time 10/18/2025 8:00am
Bearuno wrote:
As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.Heck, I had a bunch of...

20251018 151425As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.

Heck, I had a bunch of older shocks cluttering up the under bench space, and, the old beastie had a bit of a tendency towards shock fade when it was still a Linkaged bike, in some of our 4hour GNCC type races, especially at a Sand Whoop infested course.

So, grab a resi, from a 83 Floater, remove and weld up the primitive compression adjuster, make a new end cap for the shock resi, the 02 bladder and cap fitting in the 83 resi, and you've got a Hell of a lot more oil capacity. 

Shock fade : Gone. Oil would come out the same colour as it went in, whereas, std, it would come out thoroughly cooked.

I've been meaning to put one on the Ohlins TTX, but, well, I really don't come remotely close to hammering nowadays - I Plod Along, stoically. 😉

Bear, would a bigger standard reservoir provide the same results? 

Edit: if so, why wouldn’t KTM plus up the race team shocks? Could it be just appearances?

The Shop

aees
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10/18/2025 8:43am
3strokemx wrote:

They tracks arent as rough in the GP's, the shock doesnt get as hot. 😮

aees wrote:
Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get...

Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get to MXGP roughness.

Sandusky26 wrote:

Not really fair to compare the sand tracks which everyone knows gets rougher. What about all the harder pack tracks?

So KTM MXGP riders don't seem to have issues with shock on much rougher tracks than in AMA, but we should disregard that because those tracks don't count. Got it 😄

Hard packed tracks is rougher or best case same, and it's because MXGP have 2 days of racing with limited prepp, and more classes on most races.

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aees
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10/18/2025 8:48am
Bearuno wrote:
As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.Heck, I had a bunch of...

20251018 151425As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.

Heck, I had a bunch of older shocks cluttering up the under bench space, and, the old beastie had a bit of a tendency towards shock fade when it was still a Linkaged bike, in some of our 4hour GNCC type races, especially at a Sand Whoop infested course.

So, grab a resi, from a 83 Floater, remove and weld up the primitive compression adjuster, make a new end cap for the shock resi, the 02 bladder and cap fitting in the 83 resi, and you've got a Hell of a lot more oil capacity. 

Shock fade : Gone. Oil would come out the same colour as it went in, whereas, std, it would come out thoroughly cooked.

I've been meaning to put one on the Ohlins TTX, but, well, I really don't come remotely close to hammering nowadays - I Plod Along, stoically. 😉

Gravel wrote:

Bear, would a bigger standard reservoir provide the same results? 

Edit: if so, why wouldn’t KTM plus up the race team shocks? Could it be just appearances?

Space is one thing, it's fucking tight in there. And I guess just increasing the reservoir isn't giving you leverage since shock body is where most of the oil is spending most of the time.

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profmur
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10/18/2025 10:42am

Google searching indicates that across 450 brands, the oil volume in shocks is approximately 110-120ml.    So no smoking gun when it comes to wp oil volume vs showa or kyb.  

aees
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10/18/2025 11:09am
profmur wrote:
Google searching indicates that across 450 brands, the oil volume in shocks is approximately 110-120ml.    So no smoking gun when it comes to wp oil...

Google searching indicates that across 450 brands, the oil volume in shocks is approximately 110-120ml.    So no smoking gun when it comes to wp oil volume vs showa or kyb.  

It's around 500ml in a shock. But you are right in that it doesn't differ much. 

Even small changes could make a difference reg heat and cavitation.

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PRM31
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Fantasy
10/18/2025 11:19am

Maybe they got some oil that was not to spec? 

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Rotaholic
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10/18/2025 11:42am

The should just run a bladder

1
jaun
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10/18/2025 3:18pm
Rotaholic wrote:

The should just run a bladder

They do.

1
Rotaholic
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10/18/2025 3:26pm
Rotaholic wrote:

The should just run a bladder

jaun wrote:

They do.

I assumed they would use IFP as WP are a huge believer in that

1
Sandusky26
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10/18/2025 3:54pm
aees wrote:
Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get...

Its the opposite. You just look at this years sand races, AMA tracks doesn't come close. To few bikes and time on the track to get to MXGP roughness.

Sandusky26 wrote:

Not really fair to compare the sand tracks which everyone knows gets rougher. What about all the harder pack tracks?

aees wrote:
So KTM MXGP riders don't seem to have issues with shock on much rougher tracks than in AMA, but we should disregard that because those tracks...

So KTM MXGP riders don't seem to have issues with shock on much rougher tracks than in AMA, but we should disregard that because those tracks don't count. Got it 😄

Hard packed tracks is rougher or best case same, and it's because MXGP have 2 days of racing with limited prepp, and more classes on most races.

I was saying the AMA tracks are rougher, which is logical. It's hard to make bumps when they start out as hard packed freeways like some of the GP tracks. Would make sense of the KTM shock fading in AMA vs GP.

No prep can equal no bumps.

11
Bearuno
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10/18/2025 6:58pm Edited Date/Time 10/18/2025 7:13pm
Bearuno wrote:
As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.Heck, I had a bunch of...

20251018 151425As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.

Heck, I had a bunch of older shocks cluttering up the under bench space, and, the old beastie had a bit of a tendency towards shock fade when it was still a Linkaged bike, in some of our 4hour GNCC type races, especially at a Sand Whoop infested course.

So, grab a resi, from a 83 Floater, remove and weld up the primitive compression adjuster, make a new end cap for the shock resi, the 02 bladder and cap fitting in the 83 resi, and you've got a Hell of a lot more oil capacity. 

Shock fade : Gone. Oil would come out the same colour as it went in, whereas, std, it would come out thoroughly cooked.

I've been meaning to put one on the Ohlins TTX, but, well, I really don't come remotely close to hammering nowadays - I Plod Along, stoically. 😉

Gravel wrote:

Bear, would a bigger standard reservoir provide the same results? 

Edit: if so, why wouldn’t KTM plus up the race team shocks? Could it be just appearances?

Any extra Oil capacity is a Good thing, but, not a universal panacea.

A slightly larger reservoir, enabling more oil - well it won't be much of an increase.

People mostly don't know how little oil Is in the actual reservoir, given the size of a bladder / the depth of the piston setting - it is, buggerall, in the vast majority of shocks. And, you have to be cautious - you need to consider the expansion of the oil through heat. I remember at Fox, a (rough) rate of expansion was regarded as 10% - but that's just a layman's percentage: all you experts, I'm Not interested in debating numbers.... The oil expansion through heat, is the main ( of course, material expansion through heat is a part of it) reason for shock pressures to rise, If you Are using a Noble Gas, by the way. 

I've Always checked the fluid displacement into the reservoir through the shaft travel. It's good to know. In some cases, with a piston, there's scope for said piston to be set at a slightly lower depth than standard  for more oil - in some though, there can be absolutely No 'room' to play with. Bladders, well, that volume is a set thing, though, changing the actual bladder size / resi size can be an option. 

As I wrote, I had some shocks to hand, had a (slight) problem, and, as I, at the time, spent much of my days working on suspension, and wanting to minimise my time doing my Own suspension, decided to be  'Mad Scientist Bear' ( which, many will agree with my being) and made a 'something'. 

It kept me amused for the arvo it took to do it and the mount set up for the resi, and gave me better performance, and, lessened the frequency of oil changes = more time for  other Bear Brained things to do!

As to the ever raging Bladder vs Piston debates = I've been privy to many dyno runs of many shocks / forks ( and watching a 'to destruction' test of Long Travel Trophy Truck type shocks can be quite, Quite entertaining - and, it makes you grateful for the bullet proof layers of glass between you and the unit(s) being 'killed')  and have never really seen much difference in heat , or, even 'sticktion' /friction between the two 'solutions'. With the caveat of a piston set up being a Good piston setup. Bloody Hell, some can be horrendously tight!

I've a hankering to try the SKF "Piston with Membrane" set up, one day. But, like everything, I hear horror stories ( as in, them 'butterflying' over - WTF? Yikes!) about them, as well as glowing praise of them. That will be a while off, as I've fresh oil in the Ohlins, and I'm just trundling around like the Old Man That I am, at the moment, and rarely, at that.

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KurtJ99
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10/18/2025 8:42pm

I don’t think there is much heat transfer in a remote reservoir shock. The remote reservoir gives room for a bladder (in old school shocks) and enables N2 pressure to back up the seals,  provide some shock preload, and simplify rebuild ability IMO. The smaller reservoirs in modern shocks have less surface area for air cooling. But the teams know this so it’s a perplexing problem to re-emerge. 

aees
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10/19/2025 2:55am
Sandusky26 wrote:

Not really fair to compare the sand tracks which everyone knows gets rougher. What about all the harder pack tracks?

aees wrote:
So KTM MXGP riders don't seem to have issues with shock on much rougher tracks than in AMA, but we should disregard that because those tracks...

So KTM MXGP riders don't seem to have issues with shock on much rougher tracks than in AMA, but we should disregard that because those tracks don't count. Got it 😄

Hard packed tracks is rougher or best case same, and it's because MXGP have 2 days of racing with limited prepp, and more classes on most races.

Sandusky26 wrote:
I was saying the AMA tracks are rougher, which is logical. It's hard to make bumps when they start out as hard packed freeways like some...

I was saying the AMA tracks are rougher, which is logical. It's hard to make bumps when they start out as hard packed freeways like some of the GP tracks. Would make sense of the KTM shock fading in AMA vs GP.

No prep can equal no bumps.

No its not logical. A shock that barerly works on a hard packed track would be toast on a proper sand track, or even a mixed track like the ones in MXGP.

1
jaun
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10/19/2025 3:26am Edited Date/Time 10/19/2025 3:26am
Rotaholic wrote:

The should just run a bladder

jaun wrote:

They do.

Rotaholic wrote:

I assumed they would use IFP as WP are a huge believer in that

Your assumption would be incorrect.

Gravel
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10/19/2025 8:44am

My suspension guy likes bladders just because they’re easier to service/bleed than a piston.

1
outerlimits
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10/19/2025 9:12am
KurtJ99 wrote:
I don’t think there is much heat transfer in a remote reservoir shock. The remote reservoir gives room for a bladder (in old school shocks) and...

I don’t think there is much heat transfer in a remote reservoir shock. The remote reservoir gives room for a bladder (in old school shocks) and enables N2 pressure to back up the seals,  provide some shock preload, and simplify rebuild ability IMO. The smaller reservoirs in modern shocks have less surface area for air cooling. But the teams know this so it’s a perplexing problem to re-emerge. 

This made me think back to the old, giant remote reservoirs that Yamaha use to mount on the front downtube.  Funny that 40+ years later we have small reservoirs mounted above the exhaust.  Go figure. 1-copy

4
JMCR250
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10/19/2025 11:30am

Probably goes a long way towards explaining Chase's move to Kawasaki.  Does not sound good for the racing side of things.

4
mxaniac
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10/19/2025 12:33pm

This was largely expected knowing bajaj's business philosophy. I've seen past statements from leadership that indicated cutting edge R&D and racing aren't their focus.

1
10/19/2025 12:50pm
Bearuno wrote:
As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.Heck, I had a bunch of...

20251018 151425As to KTMs shock problems : it's bloody weird. How in hell can they not sort it out is beyond me.

Heck, I had a bunch of older shocks cluttering up the under bench space, and, the old beastie had a bit of a tendency towards shock fade when it was still a Linkaged bike, in some of our 4hour GNCC type races, especially at a Sand Whoop infested course.

So, grab a resi, from a 83 Floater, remove and weld up the primitive compression adjuster, make a new end cap for the shock resi, the 02 bladder and cap fitting in the 83 resi, and you've got a Hell of a lot more oil capacity. 

Shock fade : Gone. Oil would come out the same colour as it went in, whereas, std, it would come out thoroughly cooked.

I've been meaning to put one on the Ohlins TTX, but, well, I really don't come remotely close to hammering nowadays - I Plod Along, stoically. 😉

So im confused here- that additional hose & reservoir, is that full of oil or Nitrogen?
Bearuno
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10/19/2025 10:42pm Edited Date/Time 10/19/2025 11:39pm
So im confused here- that additional hose & reservoir, is that full of oil or Nitrogen?

The 'gassed' bladder is in the RM Floater era, reservoir, thence the oil in it, in the oil area space of that reservoir left by the bladder, through the RM hose ( which is a large ID hose, with large port banjo and straight fittings - not a stupidly small ID brake line and fittings ).

 The Reservoir on the original KYB shock is Full Of Oil.

Somewhere I've got notes of the extra oil capacity gained, ( I recall, vaguely, pretty much doubling the oil volume),  along with all my valving changes done to the KYB while still in use, plus all the valving I did to to Ohlins TTX I used in the PDS conversion.

I will be doing the same to the TTX shock on my PDS'd conversion. I made a landing for the resi to mount on with the Top Mounted Airfilter airbox I made for PDS set up. Just waiting on a couple of parts to come,  for an update / refresh to the Ohlins. 

2
ADynes
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10/21/2025 2:25pm Edited Date/Time 10/21/2025 2:26pm
mxaniac wrote:
The shock issue perplexes me. We've been told: KTM knows the fix but we can't have it. Why can't they have it? Does it require a frame...

The shock issue perplexes me. We've been told: KTM knows the fix but we can't have it. 

Why can't they have it? Does it require a frame or shock update?  What change resulted in the issue! Is it the shock failing or fading?

Speculation:

Did they have to jack up the nitrogen pressure to avoid cavitation? Did that increase seal drag? Did they try a low drag seal that blows?

In pondering all this, no FBD or analysis:

Initially I thought maybe they'd changed linkage or something that was working the shock harder, leading to cavitation. That lead me to thinking about shock shaft diameter, port size, oil velocity etc. How do we lower the friction in the shock. But then it occurred to me that the input is still the same. Same bumps, same system level energy going into the shock, same energy getting in to the oil. That energy going in must get out. So it's the same amount of energy that turns to heat. It doesn't seem like the cooling requirements have fundamentally changed. Given all that, perhaps to get the necessary performance they had to do SOMETHING that hurt reliability. Bigger piston ports meant piston failure, or maybe that meant thinner piston band to accommodate the ports and it fails. Similar to the early AER, maybe the shim stack requires too few shims and they can permanently deform too much. Maybe it's a low drag seal like I mentioned.

I don't have the answer, but I suspect they needed to change frame or swingarm to get the shock operating under different conditions. Conditions such that whatever they are doing to currently get the right performance doesn't push them into having an unreliable shock. It just seems like it had to be more than a cavitation or heat issue.

 

ADynes wrote:
You might not be too far off. The 350 I've been messing with the past year had a pretty bad shock valving from a VERY popular...

You might not be too far off. The 350 I've been messing with the past year had a pretty bad shock valving from a VERY popular aftermarket company. On longer motos when rough and hot oil, there wasn't a clicker/adjuster setting you could make to get the shock to not feel like complete garbage. Opened it up and found they went softer on the Cadj valving and stiffer on the main piston. Made perfect sense why it felt the way it did, it was cavitating. A stiffer Cadj and softer main made the bike actually rideable when hot. If a company that reputable can valve a WP shock so poorly for a Vet B rider, I don't think it's out of the question the factory team could be a bit off for a top pro. 

Ironically, some of the best suspension I've ridden is on my brother's Honda, tuned by the same company. 

Also interesting to note is how all over the place wp was with valving specs throughout the years/models/regions. That was surprisingly apparent even in the 10 or so OEM "shock setting sheets" I've collected. 

Just listened to Monday's Pulpmx where they called Mark Johnson of REP and asked what he thought. Sounds like he thinks it's the same thing that I found to be the problem with mine (which was valved by a factory level suspension company). 'Pressure balance' insufficient. 

2
mxaniac
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10/21/2025 4:53pm
mxaniac wrote:
The shock issue perplexes me. We've been told: KTM knows the fix but we can't have it. Why can't they have it? Does it require a frame...

The shock issue perplexes me. We've been told: KTM knows the fix but we can't have it. 

Why can't they have it? Does it require a frame or shock update?  What change resulted in the issue! Is it the shock failing or fading?

Speculation:

Did they have to jack up the nitrogen pressure to avoid cavitation? Did that increase seal drag? Did they try a low drag seal that blows?

In pondering all this, no FBD or analysis:

Initially I thought maybe they'd changed linkage or something that was working the shock harder, leading to cavitation. That lead me to thinking about shock shaft diameter, port size, oil velocity etc. How do we lower the friction in the shock. But then it occurred to me that the input is still the same. Same bumps, same system level energy going into the shock, same energy getting in to the oil. That energy going in must get out. So it's the same amount of energy that turns to heat. It doesn't seem like the cooling requirements have fundamentally changed. Given all that, perhaps to get the necessary performance they had to do SOMETHING that hurt reliability. Bigger piston ports meant piston failure, or maybe that meant thinner piston band to accommodate the ports and it fails. Similar to the early AER, maybe the shim stack requires too few shims and they can permanently deform too much. Maybe it's a low drag seal like I mentioned.

I don't have the answer, but I suspect they needed to change frame or swingarm to get the shock operating under different conditions. Conditions such that whatever they are doing to currently get the right performance doesn't push them into having an unreliable shock. It just seems like it had to be more than a cavitation or heat issue.

 

ADynes wrote:
You might not be too far off. The 350 I've been messing with the past year had a pretty bad shock valving from a VERY popular...

You might not be too far off. The 350 I've been messing with the past year had a pretty bad shock valving from a VERY popular aftermarket company. On longer motos when rough and hot oil, there wasn't a clicker/adjuster setting you could make to get the shock to not feel like complete garbage. Opened it up and found they went softer on the Cadj valving and stiffer on the main piston. Made perfect sense why it felt the way it did, it was cavitating. A stiffer Cadj and softer main made the bike actually rideable when hot. If a company that reputable can valve a WP shock so poorly for a Vet B rider, I don't think it's out of the question the factory team could be a bit off for a top pro. 

Ironically, some of the best suspension I've ridden is on my brother's Honda, tuned by the same company. 

Also interesting to note is how all over the place wp was with valving specs throughout the years/models/regions. That was surprisingly apparent even in the 10 or so OEM "shock setting sheets" I've collected. 

ADynes wrote:
Just listened to Monday's Pulpmx where they called Mark Johnson of REP and asked what he thought. Sounds like he thinks it's the same thing that...

Just listened to Monday's Pulpmx where they called Mark Johnson of REP and asked what he thought. Sounds like he thinks it's the same thing that I found to be the problem with mine (which was valved by a factory level suspension company). 'Pressure balance' insufficient. 

That means cavitation, they're likely using too much valving on the piston, which means they need a bigger shock shaft diameter.

alphado
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10/22/2025 3:19am
IMG 1963 6
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M8
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10/22/2025 4:12am
alphado wrote:
IMG 1963 6

Well in that case, maybe it’s time to sell the TE and buy a Beta..

3strokemx
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10/22/2025 5:48am Edited Date/Time 10/22/2025 5:48am
alphado wrote:
IMG 1963 6

"Survivability"

1
10/22/2025 9:55am

Sounds like Bajaj might have a different idea in mind when they say, “Ready To Race”

IMG 4487 0
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