Which suspension components should you go with? Each option comes with its own pros and cons, so the answer will depend on what you are looking to achieve. Here’s a real-world example of one recent outcome. We tested three options with AEO Powersports’ Derek Kelley and his 2024 KTM 450SXF in preparation for the 2024 outdoor season.
Derek started the day on his current base package with WP Pro Components (Cone Valve forks and a WP Trax shock). We collected base comments and made some adjustments to improve this setup. He was looking for more hold-up with better hand feel and comfort. This has been a very common complaint across the board for the 2024 KTM chassis, and, if I’m being honest, it has been a bit of a hurdle to overcome. This bike does not like to ride in the mid-stroke, which means the tuner and rider have to decide whether they want to lift the bike above the harsh spot or allow it to move easily through it to ultimately ride below this point.
The second test was with our Cone Valve fork with a crude air-assist Schrader valve that would allow us to run some outer pressure to the system on top of the normal spec with the same WP Trax shock as in the previous test. We added air pressure and sent Derek out. This resulted in the fork feeling over-sprung and still not giving the initial hold-up Derek was looking for in the fork. Though it gave great bottoming resistance, it was not comfortable. We decreased the damping and mechanical spring force for the next test. The combination of outer air pressure and a lighter mechanical spring improved his hold-up (his main concern) without sacrificing any comfort. We were now able to play with the balance between damping, spring rate and air pressure to sustain this hold-up while improving hand feel. We both were quite pleased at this point.
Next up, we threw on a production (but valved) WP fork and shock. Keep in mind that Derek came into this part of the test skeptical that it would yield any improvements. His first impression opened him up to the idea that there may be something to this setup. Our first swing was too soft, however, so I jumped in and made a damping change. Now, with a firmer setup, he came back a bit confused about how much he liked the change. He confirmed that the stock fork was a close second place to the hybrid fork setup.
We then bounced back and forth among all three configurations, tossing ideas to optimize each setup. We were able to make improvements. In the end, the hybrid fork and shock won. It had the best balance between performance and comfort. The production fork and shock combination was a close second. It was better at mid-turn and gave some added comfort but was less precise. The Cone Valve fork and Trax shock finished third. Without the added outer air pressure to the fork, balanced with a lighter mechanical spring, the bike was not working for him and the bike as a whole suffered.
Every problem has a solution, but it rarely falls into your lap.
Mark Johnson was an in-house WP suspension technician at Red Bull KTM for 10 years. He has won championships in Supercross, motocross and off-road racing. Now, Mark’s company, Research Engineering Performance or “REP,” is partnered with AEO Powersports.
Derek started the day on his current base package with WP Pro Components (Cone Valve forks and a WP Trax shock). We collected base comments and made some adjustments to improve this setup. He was looking for more hold-up with better hand feel and comfort. This has been a very common complaint across the board for the 2024 KTM chassis, and, if I’m being honest, it has been a bit of a hurdle to overcome. This bike does not like to ride in the mid-stroke, which means the tuner and rider have to decide whether they want to lift the bike above the harsh spot or allow it to move easily through it to ultimately ride below this point.
The second test was with our Cone Valve fork with a crude air-assist Schrader valve that would allow us to run some outer pressure to the system on top of the normal spec with the same WP Trax shock as in the previous test. We added air pressure and sent Derek out. This resulted in the fork feeling over-sprung and still not giving the initial hold-up Derek was looking for in the fork. Though it gave great bottoming resistance, it was not comfortable. We decreased the damping and mechanical spring force for the next test. The combination of outer air pressure and a lighter mechanical spring improved his hold-up (his main concern) without sacrificing any comfort. We were now able to play with the balance between damping, spring rate and air pressure to sustain this hold-up while improving hand feel. We both were quite pleased at this point.
This chassis has a tendency to give you the option of good handling or comfort. If you get this bike right, it is hard to watch as it wallows and kicks through rough sections of the track. The hybrid setup for him was a step in the right direction for both concerns.
Next up, we threw on a production (but valved) WP fork and shock. Keep in mind that Derek came into this part of the test skeptical that it would yield any improvements. His first impression opened him up to the idea that there may be something to this setup. Our first swing was too soft, however, so I jumped in and made a damping change. Now, with a firmer setup, he came back a bit confused about how much he liked the change. He confirmed that the stock fork was a close second place to the hybrid fork setup.
We then bounced back and forth among all three configurations, tossing ideas to optimize each setup. We were able to make improvements. In the end, the hybrid fork and shock won. It had the best balance between performance and comfort. The production fork and shock combination was a close second. It was better at mid-turn and gave some added comfort but was less precise. The Cone Valve fork and Trax shock finished third. Without the added outer air pressure to the fork, balanced with a lighter mechanical spring, the bike was not working for him and the bike as a whole suffered.
Every problem has a solution, but it rarely falls into your lap.
Mark Johnson was an in-house WP suspension technician at Red Bull KTM for 10 years. He has won championships in Supercross, motocross and off-road racing. Now, Mark’s company, Research Engineering Performance or “REP,” is partnered with AEO Powersports.