KTM Forks On Husky

Tomok
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241
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9/10/2010
Location
Epping, NH, USA

Trying to put my KYB converted AER forks on new Husky. The stock Husky forks are 10mm shorter. I tried raising the KYB forks an additional 10mm and just doesn't seem right. Fork height is 18 mm above the clamp. Fork cap is hitting bars. What am I  misunderstanding ?

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Factor E
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9/22/2011
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7/25/2026 5:44pm

What year is bike

FGR01
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Fantasy
7/25/2026 5:44pm

Sometimes when converting AER to KYB, the length changes, depending on what exact KYB cartridge is used.   So, your forks may not be exactly 10mm longer than the Husky forks.  Put them side by side and measure.     User @cwtoyota on here is very knowledgeable about these conversions and the differences.  He'll probably chime in.

Tomok
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Epping, NH, USA
7/25/2026 6:30pm
Factor E wrote:

What year is bike

2025 TC300

Tomok
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241
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Epping, NH, USA
7/25/2026 6:32pm
FGR01 wrote:
Sometimes when converting AER to KYB, the length changes, depending on what exact KYB cartridge is used.   So, your forks may not be exactly 10mm...

Sometimes when converting AER to KYB, the length changes, depending on what exact KYB cartridge is used.   So, your forks may not be exactly 10mm longer than the Husky forks.  Put them side by side and measure.     User @cwtoyota on here is very knowledgeable about these conversions and the differences.  He'll probably chime in.

I've read that before. I put them side by side and KYB is definitely longer. I didn't measure but eye balling looked close to 10mm

The Shop

Tomok
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Location
Epping, NH, USA
7/25/2026 6:35pm

I kept one stock leg on and mounted the kyb and got the axel to go through both legs with no resistance but fork height seems really high 

cwtoyota
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Tacoma, WA, USA
7/26/2026 12:41pm
FGR01 wrote:
Sometimes when converting AER to KYB, the length changes, depending on what exact KYB cartridge is used.   So, your forks may not be exactly 10mm...

Sometimes when converting AER to KYB, the length changes, depending on what exact KYB cartridge is used.   So, your forks may not be exactly 10mm longer than the Husky forks.  Put them side by side and measure.     User @cwtoyota on here is very knowledgeable about these conversions and the differences.  He'll probably chime in.

Tomok wrote:

I've read that before. I put them side by side and KYB is definitely longer. I didn't measure but eye balling looked close to 10mm

The assembly length depends on the parts you used and some other factors.
Did you buy the forks as is, or did you install the KYB setup yourself?

WP / KTM air forks are measured from the center of the axle to the top of the upper tube, excluding the fork cap.
Stock AER-48 forks from 2016 to 2020 models are 950mm in length with a 577mm upper tube.
2021+ KTM, GasGas and Rockstar Editions all have the same 950mm in length with a 577mm upper tube.
2021+ Husqvarna standard motocross models are 940mm in length with a 567mm upper tube.

I don't like seeing forks that end up more than a few millimeters over the stock length.
Increased fork length decreases the distance between the bushings.
I advise against assembling forks longer than 953mm with the 577mm upper tubes.
I advise against assembling forks longer than 943mm with the 567mm upper tubes.

In my experience, a slightly shorter fork works well on the last two generations of KTM chassis.

I have some information on KYB cartridges at the link below that may or may not be helpful.
https://dialedmfg.com/technical-information.html

3
Tomok
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Epping, NH, USA
7/26/2026 2:00pm

I bought them used. They were converted AER to KYB by Powerband. Thanks for the info 

1
wrc777
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5/21/2020
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Greenwood, IN, USA
Fantasy
7/27/2026 4:31am

For reference the CC forks used on the XC bikes are 10mm shorter than AER on the equivalent SX. That difference has something to do with the AER having a bypass slot to let the positive and negative air chambers equalize. The AER will sag more when you initially load it from fully extended and you are looking for a consistent sag between the two forks.

GPrider
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4/10/2014
Location
La Mesa, CA, USA
7/27/2026 2:27pm
Tomok wrote:
I kept one stock leg on and mounted the kyb and got the axel to go through both legs with no resistance but fork height seems...

I kept one stock leg on and mounted the kyb and got the axel to go through both legs with no resistance but fork height seems really high 

haha, I have the exact same scenario. Put my kyb conversion from my ktm on my Husky, one side only, and matched up the axle to slide through. The top of the fork was hitting my bars so decided against it. Way longer!

1
Tomok
Posts
241
Joined
9/10/2010
Location
Epping, NH, USA
7/27/2026 4:56pm
Tomok wrote:
I kept one stock leg on and mounted the kyb and got the axel to go through both legs with no resistance but fork height seems...

I kept one stock leg on and mounted the kyb and got the axel to go through both legs with no resistance but fork height seems really high 

GPrider wrote:
haha, I have the exact same scenario. Put my kyb conversion from my ktm on my Husky, one side only, and matched up the axle to...

haha, I have the exact same scenario. Put my kyb conversion from my ktm on my Husky, one side only, and matched up the axle to slide through. The top of the fork was hitting my bars so decided against it. Way longer!

Having Factory Connection shorten them 10mm. 

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