KTM Xplor Suspension (2017–2023) — What We Found, What We Fixed, and Why It Works

We’ve spent a lot of time on these bikes.

KTM, Husqvarna and GasGas EXC models from 2017 through to 2023 all ran the Xplor platform — and over the years we’ve tested them across multiple bikes, riders and conditions.

250s, 300s, 350s, 450s and 500s. 
Different riders. Different speeds.

Same problems.

And we didn’t just feel it in the workshop — we felt it out on the trail, in the bush, and at race pace.

The First Ride — And the Wake-Up Call

Our first proper test on an early Xplor-equipped bike back in 2017 wasn’t just a quick spin — we went out with one of the KTM guys to our local test loop at the time.

It had everything:

• Fast grass track sections
• Tight bush trails
• Water washouts

A proper mix — the kind of terrain that tells you very quickly what a bike is doing. At first, it felt okay. But then we hit the washouts at speed… And that’s where it all came unstuck.

The fork blew straight through the stroke and bottomed hard. Not just rough —
full-stroke, metal-to-metal, something’s-not-right hard.  I handed that bike back thinking I might have damaged it — that’s how bad the hit was.

From that moment on, it was clear:

👉 No real hold-up
👉 No progression
👉 No control when it mattered

And once you feel that at speed —
you lose confidence straight away.

What Was Actually Wrong

Across every bike we tested, the issues were consistent.

Fork (Xplor) Issues

• No real mid-stroke support
• Blowing through on bigger hits
• Lack of progression
• Later models reduced bottoming… but became harsh
• Split-function design limiting balance and feel

-You either had soft and diving, or harsh and unpredictable
-Never both comfort and control

Shock Issues — Where It Really Showed

The fork wasn’t the only problem.

The EXC PDS rear shock had its own issues — and we really felt it once we started doing bigger rides.

A lot of our testing was out at Neerim — proper terrain, long rides, square edges, roots… the kind of stuff that builds fatigue over time.

And that’s where the shock really showed its flaws.

- It felt harsh on the initial hit
- Sat low in the stroke
- And over time… it just got worse

By the end of a ride, it was hammering our backs out.  Not in a good way —
just a constant, fatiguing, dead feeling through the rear.

The more you rode it, the more obvious it became.

-No traction
- No energy return
-Just low, flat and harsh

What Was Causing It

• OEM spring rate too soft (based around ~70kg rider)
• Shock trying to hold the bike up with damping instead of spring
• Restricted initial movement = harshness
• Low ride height = poor balance

- A combination that simply didn’t work in real riding conditions

What We Changed — GEN2 Xplor Setup

We didn’t just tweak settings —
we changed how the system works.

Fork — Full Function + Flow Adjuster Control

First step was fixing the fundamentals.

We converted the forks into a true dual-function system —
both legs working together properly, like a conventional fork should.

That alone improved balance and feel straight away.

But the real game changer…

Krooztune Flow Adjuster

This is where the fork comes alive.

The Flow Adjuster gives you a level of adjustability that the standard Xplor fork simply doesn’t have.

- You can go from:

• Softer, more supportive MX-style feel
• To
• Ultra-plush, free-moving single trail setup

And you can do it in seconds with click adjustments.

No pulling forks apart.
No guesswork.
No compromise.

What That Means on the Bike

• Open it up → plush, compliant, tracks everything
• Dial it in → more hold-up, more support, better for speed and hits

You’re not locked into one setup anymore.

-One bike can now:

• Ride comfortably in tight, technical terrain
• Then handle faster sections and bigger impacts without falling apart

That’s the difference.

Shock — Plush Where It Matters, Support Where You Need It

We approached the shock to match the fork.

• Opened up the initial bleed → real plushness
• Installed correct spring rates for real riders
• Removed harsh spike on square edge hits
• Added a nitrogen bladder conversion for consistency

Once the spring rate and damping worked together properly…

-The rear sat higher
-The bike balanced front to rear
-Traction improved instantly

And most importantly: No more getting smashed through the back after a long ride, From getting hammered at Neerim…to riding all day without that fatigue.

The Result

This setup has been proven over years.

• Tested across all EXC capacities
• Used by trail riders, racers and hard enduro riders
• Refined through real-world riding, not just theory

And the feedback is always the same: More comfort,  More control, More confidence and less fatigue

Husqvarna XACT Shock — A Better Starting Point

The Husqvarna models running the XACT shock (linkage rear end) were a clear step ahead of the PDS Xplor setup. Straight up, they had better feel, more control and didn’t suffer from that same harsh, wooden action. That said, they still weren’t perfect — spring rates were off for most riders over 75kg and they lacked true plushness over repeated hits. We had alot of success on hard enduro with the oem spring woth heavier riders but with a more true to weight spring, a nitrogen bladder conversion and proper valving, they came up really well — delivering a much more consistent, plush and controlled ride.

 

 Why This Matters Now

These bikes are still everywhere.

And a lot of riders are still putting up with suspension that:

• Feels harsh
• Lacks confidence
• Doesn’t suit real-world riding

Krooztune Xplor Setup Package — Still readily Available

We’re offering a complete setup package for 2017–2023 KTM / Husqvarna / GasGas EXC models at discounted rates now we have an easy solution.  

Built from everything we’ve learned developing this system.

Options Includes:

• Full suspension service
• GEN2 Xplor fork upgrade
• Krooztune Flow Adjuster system
• Shock revalve + setup
• Correct spring rate selection
• Optional lowering setup ( using CNC machined kit parts)
• Full install and setup

What You Get:

• Plush feel with real hold-up
• Fork adjustability that actually works
• Balanced front-to-rear performance
• A bike that adapts to how and where you ride

The Offer

We’re making this setup more accessible with a special package price
based on the success of this system and the number of riders still on these bikes.

If you’ve been thinking about getting your suspension sorted —
this is the time to do it properly. Give us a call and mention this for a minimum of 20% off these dialled in setups.

If you’re still on an Xplor-equipped bike…

This is the upgrade that transforms it.