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Photo by Andy Miller, UK, Taking a rest, Jokulsarlon, Iceland

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Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



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  #1  
Old 7 Jun 2005
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fork seals on KTM640 adventure
Have blown front fork seal on bike and only done 6000km . 600km on good smooth dirt is this a problem with these bikes?

Regards Dave

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  #2  
Old 8 Jun 2005
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Dave,
it's just the beginning

Steve
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Old 8 Jun 2005
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As i am finding out try and get service from the dealers in South Africa. Is the KTM factory in austria not concerned or are they to stupid
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Old 8 Jun 2005
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Did you remember to regularly release the bleed valves on the top of the fork legs? Mine seem to need doing every 10 miles or so! There always seems to be pressure there.....

Dave
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  #5  
Old 8 Jun 2005
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This is a very common problem.Try bleeding the forks,and then very carefully cleaning around the lip of the fork seals.Folks have had good luck using thin feeler gauges, the end of a piece of 35mm film ,and business cards.Just be carefull not to cut the seals.a build up air pressure inside the fork legs causes the oil seals to weep oil.also riding in very abrasive mud can wear the seals out.I always carry a spare set on long trips,as they are often a special order item.
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Old 8 Jun 2005
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I second the tip on bleeding the forks - it may cure the problem. I've also fitted some neoprene gaters on my bike - no leaks after 12000 miles including lots of off-tarmac (fingers crossed).
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Old 8 Jun 2005
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Quote:
Originally posted by Ian:
I second the tip on bleeding the forks - it may cure the problem. I've also fitted some neoprene gaters on my bike - no leaks after 12000 miles including lots of off-tarmac (fingers crossed).
Just got bike back had neopreen gators fitted thanks to all for the info also fingers crossed
Thanks dave

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Old 4 Aug 2005
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Anyone got any 'top tips' for replacing the seals (2002 Adventure) ive got one leaking - looking at the repair manual it doesnt look to bad - how do you reseat the new seal without the KTM 'special tools' - ??? any other tips for doing this on the road welcome.
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Old 5 Aug 2005
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Grif,
You can use the old seals to drift the new ones in, cut them off after. If you cut them first but it makes it a little harder as they tend to spring open a bit.

Fit some gaiters and the seals last much longer, if you are on the road a front wheel inner tube cut up works for a time, hold it in place with some cable ties.

Steve
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Old 26 Aug 2005
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thought id try the 35mm film + fork oil trick before changing seal - pulled some dirt out and now no leak - sweet - neoprenes on, and no problems since with regular bleeding
- Cheers Steve for the top tips....
Grif
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  #11  
Old 15 Dec 2005
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My fork seals have been badly leaking for a few thousand kms now, and as I don't carry replacement seals, I am probably another 2,000kms from a dealership where I can have the seals replaced.

Assuming the seals keep leaking, is there likely to be any permanent damage from a fork that has no oil, or is it just likely to reduce my front suspension performance in the short term?
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Old 16 Dec 2005
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the fork oil is a hydraulic fluid that is circulated thru a system of shims and valves.With a loss of fluid, you will lose some shock rebound control.I don't see how you would damage the shock by continuing to ride, except maybe under very abusive conditions.You can top off the oil by using 10 weight automatic transmission fluid (not ideal but close enough).
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Old 24 Dec 2005
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I agree with neoprene fork gaiters. I have always used them and never (touch wodd) had a fork seal go.

Try sommers.

As for the air pressure release I was told last week that you'll always get pressure build up as the forks get hot. The release is only necessary for racing. (I must try it when theyre cold). Thus if you're road riding the pressure will dissipate when the forks cool down.

Sort of sounds logical

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