Align the Front End on a 2000‐2007 Suzuki DRZ 400s or 2009 KTM 450 XC‐W Motorcycle

Motorcycles can be dangerous if the front end is not straight. Any slight jar like a pothole, speed bump, curb, or rock can cause the front wheel to need alignment. This tutorial will demonstrate how to align a motorcycle front end on a 2009 KTM 450 XC-W and 2000-2007 DRZ 400s but the basic steps are the same for most motorcycles.

Steps

  1. Loosen the front wheel axle nut. 27mm socket for KTM. DRZ uses 24mm socket on one end and 19mm hex tool on the other end.
  2. Loosen the four bolts clamping the axle to the forks (2 on each fork). 10mm socket for KTM. 12mm socket for DRZ.
  3. Loosen the four bolts holding the forks in the lower triple clamp. (2 bolts on each fork). 10mm socket for KTM. 12mm socket for DRZ.
    • Do not loosen the top triple clamp as this would result in the forks completely sliding up through the triple clamp assembly.
  4. Bounce the front end up and down 4 or 5 times. This is what allows the front wheel to find its natural centered position.
    • Do this by compressing the shocks with the front brake lever squeezed.
  5. Tighten the four bolts of the lower triple clamp back up. The 2009 KTM 450 XC-W torque value is 8.9 lb.ft and socket size is 10mm. The 2000-2007 DRZ 400s torque value is 23.0 lb.ft. and socket size is 12mm.
  6. Tighten the front wheel axle to an initial torque value. The 2009 KTM 450 XC-W is 33.2 lb.ft using the 27mm socket. The 2000-2007 DRZ 400s is 14.5 lb.ft. using the 24mm socket on one end while holding the other end with the 19mm hex tool.
  7. Bounce the front end up and down again. Do this 4 or 5 times by compressing the shocks with the front brake lever squeezed.
  8. Tighten the four axle clamp bolts. They are located at the bottom of the forks and were loosened earlier. The 2009 KTM 450 XC-W torque value is 11.1 lb.ft. and socket size is 10mm. The 2000-2007 DRZ 400s torque value is 13.0 lb.ft.and socket size is 12mm.
    • At this point motorcycles can differ as to the procedure of tightening the front wheel axle. The KTM is done! Suzuki DRZ owners please continue to the next step.
  9. Tighten the front axle nut again to a final torque value. 2000-2007 DRZ 400s torque value is 30.5 lb.ft. using a 24mm socket on one end while holding the other end with the 19mm hex tool. This step is only for certain model motorcycles.

Warnings

  • Individual motorcycle owners must assume all risk while conducting this procedure.

Things You'll Need

  • DRZ: 12mm and 24mm sockets, 19mm hex tool, ratchet(socket wrench), extension, breaker bar, and torque wrench; also 1/2" to 3/8" and/or 3/8" to 1/4" drive adapters (depending on socket set drive size being used)
  • KTM: 10mm and 27mm sockets, ratchet(socket wrench), extension, breaker bar, and torque wrench; also 1/2" to 3/8" and/or 3/8" to 1/4" drive adapters (depending on socket set drive size being used)

References

  • KTM-Sportmotorcycle AG (2010). KTM: Repair manual 2009. Mattighofen, Austria: KTM-Sportmotorcycle AG.
  • Suzuki Motor Corporation (2007). Suzuki DR-Z400: M.Y 2000-2007 Service manual. Minami-ku, Hamamatsu: Suzuki Motor Corporation.
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