2025 ktm xact aer forks

sutton33us
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9
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1/18/2026
Location
Sint-Maartensdijk NL

My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly but that didn't help

I want to open them up to see if the first owner maybe put too much oil in it or wrong seals

The left forkcap looks like this,i don't see the black plug in the manual pictures:

What is it for ?

6176
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wrc777
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Greenwood, IN US
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4/13/2026 10:44am

The black plug stays in. You can ignore it. 

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cwtoyota
Posts
2380
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3/11/2013
Location
Tacoma, WA US
4/14/2026 12:39pm
sutton33us wrote:
My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly...

My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly but that didn't help

I want to open them up to see if the first owner maybe put too much oil in it or wrong seals

The left forkcap looks like this,i don't see the black plug in the manual pictures:

What is it for ?

6176

Have you opened up the bleeder screws (small Torx screws) on both fork legs before each ride?

(Lots of people are unaware that they need to bleed the air-spring side of these WP forks)

It's possible there is too much oil in the outer legs if it is too firm at the bottom half of the stroke.
Which bike do you have and what's your weight?  Are you riding Moto?  Off-Road?
(130psi is firm for a light guy on a 125SX and soft for an average guy on a 450SX-F).
 

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sutton33us
Posts
9
Joined
1/18/2026
Location
Sint-Maartensdijk NL
4/14/2026 10:58pm
sutton33us wrote:
My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly...

My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly but that didn't help

I want to open them up to see if the first owner maybe put too much oil in it or wrong seals

The left forkcap looks like this,i don't see the black plug in the manual pictures:

What is it for ?

6176
cwtoyota wrote:
Have you opened up the bleeder screws (small Torx screws) on both fork legs before each ride?(Lots of people are unaware that they need to bleed...

Have you opened up the bleeder screws (small Torx screws) on both fork legs before each ride?

(Lots of people are unaware that they need to bleed the air-spring side of these WP forks)

It's possible there is too much oil in the outer legs if it is too firm at the bottom half of the stroke.
Which bike do you have and what's your weight?  Are you riding Moto?  Off-Road?
(130psi is firm for a light guy on a 125SX and soft for an average guy on a 450SX-F).
 

Thanks for your reply.

I have gone through all the basic steps again

It is my sons bike by the way,a 2025 ktm sx 250,he weighs about 83kg with full gear

I opened the bleeder screws again and a lot of air escaped,so that will help.

But i found out he had a collision with another rider on the side off his forks and i loosend the  axle clamp and the fork popped out almost 5mm.

All those things together probably explain the stiff feeling.

We will try on the track again with 140 psi and see how it handles now

Free sag on the rear is 35mm so that should be oke.

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wrc777
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3124
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Location
Greenwood, IN US
Fantasy
4/15/2026 11:51am
sutton33us wrote:
My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly...

My 2025 xact aer forks feel very stiff,i set the air pressure as low as 130 psi and made sure the forks are lined up correctly but that didn't help

I want to open them up to see if the first owner maybe put too much oil in it or wrong seals

The left forkcap looks like this,i don't see the black plug in the manual pictures:

What is it for ?

6176
cwtoyota wrote:
Have you opened up the bleeder screws (small Torx screws) on both fork legs before each ride?(Lots of people are unaware that they need to bleed...

Have you opened up the bleeder screws (small Torx screws) on both fork legs before each ride?

(Lots of people are unaware that they need to bleed the air-spring side of these WP forks)

It's possible there is too much oil in the outer legs if it is too firm at the bottom half of the stroke.
Which bike do you have and what's your weight?  Are you riding Moto?  Off-Road?
(130psi is firm for a light guy on a 125SX and soft for an average guy on a 450SX-F).
 

sutton33us wrote:
Thanks for your reply.I have gone through all the basic steps againIt is my sons bike by the way,a 2025 ktm sx 250,he weighs about 83kg...

Thanks for your reply.

I have gone through all the basic steps again

It is my sons bike by the way,a 2025 ktm sx 250,he weighs about 83kg with full gear

I opened the bleeder screws again and a lot of air escaped,so that will help.

But i found out he had a collision with another rider on the side off his forks and i loosend the  axle clamp and the fork popped out almost 5mm.

All those things together probably explain the stiff feeling.

We will try on the track again with 140 psi and see how it handles now

Free sag on the rear is 35mm so that should be oke.

Reset those axle clamps every ride day or anytime the fork feels bound up. 

1

The Shop

lumpy790
Posts
11279
Joined
9/18/2007
Location
York, SC US
4/15/2026 12:15pm

Let the air out on both sides. If it doesn't compress its possibly 1 fork spring in 1 side. 

My Rockstar Edition had the 1 spring setup on it that was added to it before I bought it with this cap on that side. 

IMG 2424 9
1
U3
Posts
74
Joined
9/9/2011
Location
DE
4/19/2026 1:25am

Your air pressure is way way to low!

You should be around 155-156psi.

I started with 10,8bar/157psi and ended at 10,9bar/158psi at 90kg naked. Measured with warm forks after the first turn and bike at the stand with both wheels of the ground. Air pressure is crucial within 1psi. Try to get a digital shock/fork pump with a no air loss adapter like Topeak Pocketshock digital or the digital RockShox pump. Makes adjusting and fine tuning air pressure a lot easier. Save the original WP pump for bigger air pressure changes.

My SX250 2025 forks and shock are really really good right now. Never thought I'll say this about a stock suspension!

sutton33us
Posts
9
Joined
1/18/2026
Location
Sint-Maartensdijk NL
4/19/2026 2:15am Edited Date/Time 4/19/2026 2:16am
U3 wrote:
Your air pressure is way way to low!You should be around 155-156psi.I started with 10,8bar/157psi and ended at 10,9bar/158psi at 90kg naked. Measured with warm forks...

Your air pressure is way way to low!

You should be around 155-156psi.

I started with 10,8bar/157psi and ended at 10,9bar/158psi at 90kg naked. Measured with warm forks after the first turn and bike at the stand with both wheels of the ground. Air pressure is crucial within 1psi. Try to get a digital shock/fork pump with a no air loss adapter like Topeak Pocketshock digital or the digital RockShox pump. Makes adjusting and fine tuning air pressure a lot easier. Save the original WP pump for bigger air pressure changes.

My SX250 2025 forks and shock are really really good right now. Never thought I'll say this about a stock suspension!

Does your setup soak up the small stuff like breaking bumps?

Thats where my forks feel very harsh.

What is your skill level?

 

U3
Posts
74
Joined
9/9/2011
Location
DE
4/21/2026 9:51pm

Your forks must feel harst with that Setup, it rides way to Low coming into braking bumps. 

Don't confuse Speed with weight. You need to Setup your Bike for your weight with the right spring and sag and the right Air pressure. There are Personal preferences and what you Ride (SX, MX, woods) that May Change that a bit, but Not that much.

Damping Setup ist where your Speed comes really into Play.

Try those Base settings for your forks and Ride. 

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