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Suspension Sag Setup Tutorial - KTM 300 XC-W & Husqvarna TE 300

Step-by-step guide to setting proper suspension sag on your KTM 300 XC-W or Husqvarna TE 300 for optimal hard enduro performance.

Suspension Sag Setup Tutorial

Quick Reference - Target Sag Numbers

KTM 300 XC-W & Husqvarna TE 300

  • Race Sag (Rear): 105-110mm
  • Free Sag (Rear): 35-40mm
  • Fork Sag: 45-55mm (rider on bike)

Tools Required

  • Tape measure or sag scale
  • Marker or tape for reference points
  • Friend to help (highly recommended)
  • Bike stand (optional but helpful)
  • 24mm wrench (shock preload)
  • Hammer and punch (shock collar)

Step-by-Step Rear Sag Setup

Step 1: Prepare the Bike

  1. Place bike on level ground
  2. Ensure correct tire pressure (12-14 PSI)
  3. Remove any cargo/accessories
  4. Clean shock area for clear measurements

Step 2: Measure Fully Extended

  1. Lift rear wheel off ground completely
  2. Let suspension fully extend
  3. Measure from rear axle to a fixed point on fender
  4. Mark or note this measurement (L1)
  5. Typical measurement: 620-640mm

Step 3: Measure Free Sag

  1. Let bike settle on ground (no rider)
  2. Bounce rear slightly and let settle
  3. Measure same points (L2)
  4. Free sag = L1 - L2
  5. Target: 35-40mm

Step 4: Measure Race Sag

  1. Put on all riding gear
  2. Mount bike in riding position
  3. Have helper balance bike
  4. Stand on pegs, riding stance
  5. Bounce suspension and let settle
  6. Helper measures same points (L3)
  7. Race sag = L1 - L3
  8. Target: 105-110mm

Step 5: Adjust Preload

  • Too much sag (>110mm): Increase preload
  • Too little sag (<105mm): Decrease preload
  • One full turn = approximately 3mm change

Front Fork Sag Setup

Measuring Fork Sag

  1. Zip-tie on fork tube at dust seal
  2. Lift front wheel off ground
  3. Measure exposed chrome (L1)
  4. Set bike down, rider in position
  5. Bounce forks, let settle
  6. Measure to zip-tie (L2)
  7. Fork sag = L1 - L2
  8. Target: 45-55mm

Adjusting Fork Preload

  • Remove fork caps (bike supported)
  • Add/remove preload spacers
  • 5mm spacer = ~5mm sag change
  • Maintain equal spacers both sides

Utah Hard Enduro Specific Settings

Rock Gardens

  • Race sag: 108-110mm (softer for compliance)
  • Fork sag: 50-55mm (more initial travel)
  • Benefit: Better traction on loose rocks

Technical Climbs

  • Race sag: 105-107mm (less sag)
  • Fork sag: 45-50mm (less dive)
  • Benefit: Maintains geometry on steep terrain

High Speed Sections

  • Race sag: 105mm (balanced)
  • Fork sag: 45-50mm (stability)
  • Benefit: Predictable handling

Troubleshooting Common Issues

Problem: Can’t Achieve Proper Free Sag

Too much free sag (>40mm):

  • Spring too soft
  • Need heavier spring rate

Too little free sag (<35mm):

  • Spring too stiff
  • Need lighter spring rate

Problem: Bike Feels Harsh

  • Check race sag first
  • May have too little sag
  • Reduce preload 2-3 turns
  • Recheck measurements

Problem: Bottoming on Small Hits

  • Too much sag
  • Increase preload
  • Check spring rate calculation
  • Consider revalve if spring correct

Sag Quick Check Method

Trail-Side Verification

  1. Stand next to bike
  2. Mark dust seal position
  3. Sit on bike in gear
  4. Have buddy check movement
  5. Should be about 2 fingers width

Visual Indicators - Correct Sag

  • Bike sits level or slightly nose-down
  • Rear wheel follows ground contours
  • No excessive squat under acceleration
  • Predictable behavior over obstacles

Advanced Considerations

Linkage Ratio Effects

The KTM/Husky PDS system is progressive:

  • Initial: 2.8:1 ratio
  • Mid-stroke: 3.2:1 ratio
  • Bottom: 3.8:1 ratio

This means small preload changes have larger effects on initial sag.

Temperature Compensation

Cold weather stiffens suspension:

  • Add 2-3mm sag for winter riding
  • Oil viscosity increases in cold
  • Seals create more friction

Altitude Adjustments

Higher elevation affects air pressure:

  • Closed cartridge forks unaffected
  • Open chamber may need adjustment
  • Typically minimal effect <10,000ft

Professional Sag Setup Service

Mountain Goat Sports offers complete sag analysis:

  • Precise measurement tools
  • Rider weight in gear
  • Spring rate verification
  • Preload optimization
  • Test ride evaluation
  • Written setup sheet

Key Points to Remember

  1. Always measure with riding gear on
  2. Free sag tells you about spring rate
  3. Race sag affects bike behavior
  4. Small changes make big differences
  5. Document your settings
  6. Recheck after spring break-in

Setup Log Template

Date: _______
Rider Weight (gear): _______
Spring Rates: Fork _____ Shock _____
Race Sag: _______mm
Free Sag: _______mm
Fork Sag: _______mm
Preload Turns from Min: _______
Notes: _______________________

Keep this log to track changes and find your perfect setup for different Utah riding areas.

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